Set Construction

You want your video to look top-tier, and we get it—so do we. That’s exactly why we’re kicking off this little blog series: A Complete Guide to Video Production. Get ready to dive in to all aspects of video production: set construction, graphic design, producing, directing, and more!

Naturally, we’re starting off the series by highlighting our set builder, electric support, camera operator, and overall backbone of our video production: Luke (who we endearingly call the Luke-of-All-Trades). Keep reading to see how his set construction turns bland backgrounds into glorious spectacles of awesomeness (we’re talking sliding and tilting sets, custom sound treatment, and personalized signs). Luke pulls back the curtain (literally) to show you how the magic happens, from hammering in nails to polishing the final product. Journey back in time all the way back to his first set construction project in 2017 to the latest and greatest in 2024. Uncover the step-by-step build process, begin building, challenges he ran into, and how these sets elevate the overall video production quality of each project.

Who is this Film Production Guide For?

• Decision-Makers in Marketing Departments
• Business Directors
• Entrepreneurs
• Set Builders
• Key Players in Corporate Communications
• Seekers of Complete Video Production Solutions

Introduction to Set Construction

Set construction is a crucial element in film production that sets the stage for the story and immerses the audience in the film’s world. Imagine watching a movie where the background doesn’t quite match the narrative—pretty jarring, right? That’s where set construction comes in. It involves designing and building a physical space to create the desired look and feel of a scene, making sure every detail aligns with the story being told.

The set construction process is no small feat. It requires meticulous planning, coordination, and a lot of hard work from a dedicated team of professionals. This team includes the production designer, who guides the overall aesthetic; the art director, who brings the visual elements to life; the construction department, which handles the actual building; and the set designer, who creates detailed blueprints. Each role is a crucial element in ensuring the set not only looks fantastic but also functions perfectly for filming.

In this section, we’ll dive into the basics of set construction and explore why it’s such an essential part of film production. From the initial concept to the final build, you’ll get a behind-the-scenes look at how these incredible movie sets come to life.

Key Roles in Set Construction

Creating a movie set is a team effort, and each member plays a vital role in bringing the director’s vision to life. Let’s break down the key roles in set construction:

• Production Designer: Think of the production designer as the mastermind behind the overall look and feel of the film. They work closely with the director to ensure that every visual element aligns with the story. From the color palette to the architectural style, the production designer’s vision sets the tone for the entire film.
• Art Director: The art director takes the production designer’s vision and makes it a reality. They oversee the creation of the visual elements, including the set design and construction. Their job is to ensure that every detail, no matter how small, contributes to the film’s aesthetic.
• Construction Department: This is the team that gets their hands dirty. The construction department is responsible for building and assembling the sets according to the models and concepts provided by the art department. They’re the ones hammering nails, painting walls, and making sure everything is structurally sound.
• Set Designer: The set designer creates detailed blueprints and drawings for each set based on the script’s requirements. They work closely with the production designer and art director to ensure that every element is accurately represented in the final build.
• Construction Coordinator: The construction coordinator is the project manager of the set construction process. They handle budgeting, scheduling, and implementation of designs, ensuring that the set is built on time and within budget. Their organizational skills keep the entire construction team on track.
• Set Decorator: Once the set is built, the set decorator steps in to add the finishing touches. They choose and arrange furniture, add decorative elements, and ensure that all props are in place and ready for filming. Their work brings the set to life, making it feel authentic and lived-in.

Each of these roles is essential to the set construction process, and together, they create the stunning backdrops that make movies so visually captivating.

Pre-Construction Planning

Before the first nail is hammered or the first wall is painted, there’s a lot of groundwork that needs to be laid. Pre-construction planning is a critical phase in the set construction process, ensuring that everything runs smoothly and stays within budget. Here’s what it involves:

• Location Scouting: The first step is finding the perfect locations for filming. This could be an existing location that fits the script’s needs or a studio where sets can be built from scratch. Location scouting is all about finding spaces that enhance the story while being practical for filming.
• Script Analysis: Next, the production team dives into the script to determine the specific locations and types of sets required. This analysis helps in creating a detailed plan for the set construction process, ensuring that every scene has the perfect backdrop.
• Set Design: With the script analyzed, the set designer creates detailed blueprints and drawings for each set. These designs are based on the script’s requirements and the production designer’s vision, providing a clear roadmap for the construction team.
• Budgeting: Building a set can be expensive, so careful budgeting is essential. The construction coordinator estimates the cost of materials, labor, and equipment needed to bring the set to life. This step ensures that the project stays within financial constraints.
• Scheduling: Finally, a timeline is created for the construction process. This schedule outlines when each phase of the build will take place, ensuring that the set is ready for filming on time. It’s a complex puzzle, but with careful planning, everything falls into place.

Pre-construction planning is all about preparation. By laying a solid foundation, the production team ensures that the set construction process is efficient, cost-effective, and ultimately successful.

Backflip Set Construction Process: A Timeline

1. AVID Ratings (2017)

Client: Avid Ratings | Date: June, 2017

Step-By-Step Set Construction Process

This project started with the construction of the floor platform. It consisted of 6 flats, each one 6×6 feet. Don’t ask me why they are 6×6. It turns out that it is much easier to build things to standard material sizes #firsttimeonset. These were each sheathed with plywood, then painted in brand colors and finished in high gloss. I then built the tall “frosted windows.” They were constructed with 1×1 lumber, plywood, and supported with shelf brackets. If I remember correctly, the “frost” material was Lee 216 White Diffusion. The desk, TV’s and truss system were all rented.

How this Build Enhanced the Quality of Video 

The floor done up in brand colors really helped define the space and the frosted windows added a lot of depth to the set, as well as just being a fun visual element.

Challenges with this Set Construction

As I hinted at earlier this was my first real set construction project. The main challenge with the build was my decision to make the flats 6×6 instead of 4×4 or even 4×8. The sheathing process took longer as a result and I now build everything to match standard material sizes 😂

See how this set construction elevated the final video: AVID Ratings – “2017 AVID Awards”

2. Saint Ambrose Academy’s Benefit Dinner Livestream (2020)

A simpler set for a live benefit dinner. The event opens with the hosts moving through all the layers of set pieces as they walk onto set.

Client: St. Ambrose Academy | Date: December, 2020

Step-By-Step Set Construction Process

This was a pretty simple set consisting of the signs and the triangle arches. We actually had the arches sitting around from another event so we were able to repurpose them as Christmas trees. The signs themselves consisted of two parts; the letters and the black backing material. We had the backing material cut by a sign manufacturer and I cut the letters out of 3/4” MDF. Each word or phrase was rattle canned and then screwed to the backing material. Once everything was assembled I hung the signs from our grid with fishing line.

How this Build Enhanced the Quality of Video 

One way this set enhanced the production value of this event was our opening shot. The hosts start out in our green room (behind the black curtain) and on queue the camera leads them through the set revealing the staggered sign elements.

Challenges with this Set Construction

I think the most challenging parts of this one was the tedious process of cutting out all of the letters as well as hanging the sign with fishing line. So much fishing line…

See how this set construction elevated the final video: See the Joy Benefit Dinner

3. On3 (2021)

One of the more abstract sets we have designed. First time working with acrylic which was a fun challenge.

Client: On3 | Date: March, 2021

Step-By-Step Set Construction Process

Recognize anything in the photo below? Yep, that is the same floor from the Avid Ratings set, albeit with new paint. So we have the floor already. Next up are the vertical wood slats. I built these out of higher quality 1×2” pine boards. I used a scrap 1×2” to keep even spacing. The orange shapes are just painted MDF. The centerpiece to this set is the acrylic cube standing on one of it’s corners. It started out as single sheet of acrylic which I cut to size and then assembled and glued. Gluing acrylic is an interesting process because you are essentially melting the acrylic pieces together with a solvent.

How this Build Enhanced the Quality of Video

Anytime you can take a simple talking head video and elevate it with a cool and unique set is a win in my book!

Challenges with this Set Construction

The acrylic cube/On3 logo was definitely the most challenging part of this build, specifically the the little floor stand that allowed it to balance on its point. There was some tricky geometry involved.

4. Ho-Chunk Gaming Madison (2021)

This probably remains the most complicated set we have built to date. Moving walls, interchangeable floor dressing and wall panels.

Client: Ho-Chunk Gaming Madison | Date: July, 2021

Step-By-Step Set Construction Process

This build began with figuring out how to best achieve the goal of having the walls slide apart from the corner. I settled on what was basically a wide and really long skateboard, just some OSB supported by many heavy duty casters. From there the walls were assembled on top of these moving platforms, in the traditional Hollywood flat construction style, with room on the “skateboard” for sandbags and weights. As you can see in the photos we had a couple window and door flats as well. One of our scenes took place in a kitchen so I assembled and painted some cabinets as well as cut a countertop to size and installed a sink. This production had many scenes so wall coverings, set pieces, appliances, and flooring was changed out as needed.

How this Build Enhanced the Quality of Video

In this case the moving walls were a core part of the script and creative which really helped this spot stand out.

Challenges with this Set Construction

As you can probably guess getting the walls to move in a reliable, efficient (and budget friendly 😜) way was the most difficult part of this set project. In the future I would probably lean towards more of a speed rail system but the “skateboard” approach ended up working out quite well.

See how this set construction elevated the final video: Ho-Chunk Gaming Madison 2023 Commercial

5. Johnson Fitness (2021)

We can even do sound treatment!

Client: Johnson Fitness | Date: November, 2021

Step-By-Step Set Construction Process

This project was a little bit different. We were hired to do some sound treatment for a fitness company that had just moved into a new studio. It began with determining how many sound tiles would fit the space. We ended up building 16. Each tile is made up of a 1×4” frame which is packed with sound absorbing insulation and wrapped in duck canvas. After attaching some mounting hardware I was able to wire them up to the ceiling.

How this Build Enhanced Quality of their Studio Space

Less echo!

Challenges with this Set Construction

The most difficult part of this build was the actual installation. The client provided a small scissor lift but even with that they can be a bit of a bear to handle. Insulation is heavier than you think!

6. Element14 (2022)

More of an industrial look. Actual concrete coating on the walls. 

Client: Element 14 | Date: February, 2022

Step-By-Step Set Construction Process

This project started with building new extra tall Hollywood flats, 12ft to be precise. I covered all the walls in 1/8” plywood. Once that was done I came through with “Henry Feather Finish” which is a very fine cement based product. After all the walls were covered in a thin layer of concrete I added some electrical conduit and outlets to help complete the industrial look. The client also provided an electrical box that we had to incorporate into the pillar. We also needed to be able to shoot a reverse through said box, so after some modification we were able to place a camera in the pillar and see talent through the electrical box. To finish it all off we added some caution style tape to the floor.

How this Build Enhanced the Quality of Video

This set elevated the production quality of this project by allowing us to shoot in an industrial space designed exactly for our needs all while being able to control lighting and sound.

Challenges with this Set Construction

The most challenging part of this build was working with the concrete. I applied the concrete in phases with a trowel but as you can see in the photos that resulted in some noticeable starting and stopping points. If I were to try this again I would explore spraying on the concrete and troweling after.

7. Kelly Jackson (2022)

A music video! This one might actually be tied for the most complicated set. Another moving set as well as interchangeable wall panels. 

Client: Kelly Jackson | Date: April, 2022

Step-By-Step Set Construction Process

For this project the creative required a set that could be tilted backwards for a gravity shift effect. I started with building the bottom platform which would support the walls as well as be the main structural element. This consisted of 2×6” joists and OSB sheathing with an additional layer of cement board on top of the OSB for extra weight and rigidity. The wall was once again Hollywood flats, this time reused from the Element14 set. After that I added some additional bracing between the wall and floor. Next up was the tilting mechanism. The back length of the floor acted as our pivot point. This was achieved with a couple of sections of speedrail inset into two weighted 4x4s.” The other part of the tilting mechanism was the pulley system. We had lifting points on both sides of the floor and wall allowing us to lift either side depending on the required move. You can also spot a counterweight in one of the photos.

How this Build Enhanced the Quality of Video

We were able to increase the production value of this music video by turning the feeling of turmoil and chaos into a physical effect, both on set dec and talent.

Challenges with this Set Construction

The hardest part of this build was the tilting mechanism. We opted to tilt the set manually with pullies but next time I would probably try to do it with a winch of some sort.

See how this set construction elevated the final video: Kelly Jackson – Don’t Speak Music Video

8. Spectrum Brands (2024)

One of the sets we built on location for an external agency.

Client: Spectrum Brands | Date: April, 2024

Step-By-Step Set Construction Process

This build started with the process of bringing all of the flats we needed to the clients studio. Once on site we were able to starting putting up walls according to the clients planned layout. Next came paint and trim. The flooring we used for this is your typical LVP snap together flooring. After that the client’s set dec team put on the finishing touches with a little help from me for window coverings and some other small things.

How this Build Enhanced the Quality of Video

Being able to have both the benefits of the look of an on location room while also maintaining lighting and sound control in a studio is always a win.

Challenges with this Set Construction

I think the biggest challenge with this project was working in a new and unfamiliar space. There were some height and space constraints we had to work around but all in all this was a very successful build.

9. Spectrum Brands Part 2 (2024)

Another one. Same location and client.

Client: Spectrum Brands | Date: May, 2024

Step-By-Step Set Construction Process

This set was built in the same studio and with the same flats as the first one. The layout was different but the process was very similar: assemble walls, paint, trim out windows, doors, and baseboard, and lay down flooring. The final touches were once again done by the in house set dec team.

How this Build Enhanced the Quality of Video

Being able to have both the benefits of the look of an on location room while also maintaining lighting and sound control in a studio is always a win.

Challenges with this Set Construction

One of the challenges with this build was working around the large pillar you can see in most of the photos. The client was also a little short on flooring but with some well placed rugs you would never know!

10. Ho-Chunk Gaming Madison Part 2 (2024)

This was a fun one. Creating a physical sign based off of our graphic designer Hannah’s design. Still finding glitter in the studio lol.

Client: Ho-Chunk Gaming Madison | Date: June, 2024

Step-By-Step Set Construction Process

This project started with getting Hannah’s design printed to scale at FedEx. After a little modification to the height of the sign I was able to start transferring it to some 3/4” MDF. I was basically able to use the FedEx template as a stencil on the MDF. Most of the cutting was done with a jigsaw on account of the detailed design. After all my parts were cut I glued everything together. The next step was ✨glitter✨. I applied Mod Podge on the borders that were going to get glitter and then used a shaker to apply said glitter. Once the Mod Podge dried I was able to mark and drill the holes for the lights. The final steps included painting the center portion black, gluing the feather in place, and installing the lights. The circles you see in the last few photos were part of a raised platform for our talent. These were cutout with a router on a circle jig. I then glued and nailed on some risers to give me the correct height. I added some additional supports in the middle to support the weight of a person. Each platform was finished with red paint and more ✨glitter✨.

How this Build Enhanced the Quality of Video

This set added a cool twist to what could have just been a graphic or two. We also used some animation and VFX to really help the sign shine!

Challenges with this Set Construction

This project went very well over all but the most time consuming part of the process was definitely the glitter. I am still finding it around the studio 😵‍💫

11. Johnson Fitness Part 2 (2024)

The most recent project. Very symmetrical and minimalist.

Client: Johnson Fit | Date: August, 2024

Step-By-Step Set Construction Process

This project began with an onsite visit with the client to talk through what we could do with the constraints of the space. We had to work around some lighting trusses so the client decided to incorporate them into the design in the form of columns. Once the layout was finalized I was able to start framing out the walls. This was done with standard residential framing techniques, i.e. 16” OC. I had to work around some existing set walls that were in the process of being taken down so I starting hanging drywall before I finished framing. As I mentioned earlier in this blog it is much easier to work with materials in their default dimensions. It just so happened that the client wanted 12ft tall walls so it made for a lot less cutting when hanging the drywall. I then moved onto taping and mudding. This is a long and tedious process but one thing that made it easier was FibaFuse. This was my first time using it and I was thoroughly impressed!

How this Build Enhanced the Quality of Video

Combining the authentic look of an on-location room with the controlled lighting and sound of a studio is a filmmaker’s dream. It allows for a greater control and polished look to the final video that a regular environment wouldn’t necessarily lend itself to.

Challenges with this Set Construction

Working around the lighting trusses and installing the baseboard to accommodate LED strips were the most challenging parts of this set construction.

The Conclusion: Final Thoughts on the Movie Set

Thanks for tuning into the first segment of our Complete Guide to Video Production series! We hope you enjoyed delving into the details of our set construction services, masterfully executed by our Luke-of-All-Trades. If you were inspired by how we transform a concept to an impactful visual story, prepare to dig deeper into the world of video production excellence.

Our aim is to equip decision-makers like you—whether you’re a marketing manager, corporate communications head, or business owner—with the insights needed to produce compelling video content that resonates with your audience. We can’t wait to support you further in bringing your video ideas to fruition. At Backflip, we’re big believers of not just following trends—we set them, infuse them with innovation, and deliver with exceptional style. Discover our video production services or contact us today to transform your next project into a captivating experience!

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