09/19/2025
At the start of this year, we got a call from Lark Brewing in Virginia. They wanted to cover their massive 8,000 sq. ft. patio—but a louvered pergola system would have been far too expensive.
Instead, we designed a custom solution using fabric sails, which brought unique challenges:
1️⃣ Scale & layout – We needed to cover the space without cluttering the lounge areas. We identified 8 strategic points for oversized posts, either along the perimeter or near existing structures.
2️⃣ Structural stability – Each post measured 12 inches wide, 21 feet tall, and weighed over 1,000 lbs. To achieve the required 16 feet above ground while ensuring stability, we dug 8-foot-deep holes, poured a reinforced concrete base, set steel plates, then completed a second concrete pour.
3️⃣ Installation logistics – Moving and placing the posts required precision. Since heavy equipment would damage the turf, we brought in a crane that could reach 200 feet from the parking lot, lifting each post into place without ever touching the grass.
4️⃣ Sail installation – With mechanical lifts off-limits, our team engineered a custom pulley-and-winch system to manually raise and tension the sails from 200 feet away.
The result? A budget-conscious, structurally sound, and visually striking patio cover—delivered on time, without compromising the space.
Big thanks to our team, subcontractors, and the client’s crew for making this complex project a success.
