SOP
SOP Program for Themed Broadcast Set Fabrication
Purpose and Scope
This SOP defines a comprehensive Quality Assurance and Quality Control (QA/QC) program for themed fabrication in a gaming studio environment used for live dealer broadcasts or game shows. It ensures that all scenic and fabricated elements meet the highest standards of visual quality, safety, and functionality before and during use in live broadcast production. The SOP is intended for fabrication vendors, casino operations staff, and compliance teams, providing clear procedures and checkpoints from initial fabrication through installation and pre-broadcast testing. By following these guidelines, all parties can ensure theme fidelity under studio lighting, durability under high-frequency use, regulatory compliance, and a safe studio environment for staff and equipment.
Roles and Responsibilities
Fabrication Vendor: Responsible for building the themed set elements to specification and conducting in-house QA checks. Provides material certificates (fire-retardant, etc.), test reports, and documentation to the casino. Addresses any defects or non-conformances identified during inspections.
Operations Staff: Oversees delivery and installation on site. Verifies that set pieces integrate with the studio (lighting, cameras, and other infrastructure) and meet operational needs (e.g. stability, ease of use, maintainability). Coordinates any facility-related compliance (fire safety inspections, building code adherence) and ensures studio lighting and audio setups are tested with the set.
Compliance Team: Ensures that the entire setup complies with relevant gaming regulations and standards. Verifies that materials and equipment have necessary certifications (fire codes, FCC, etc.) and that the environment supports fair game operation (e.g. no interference or security gaps). Reviews and signs off at key stages (post-fabrication, post-installation, pre-broadcast) to document compliance with gaming standards (e.g. GLI requirements) and local laws.
(Note: Additional stakeholders like broadcast production crew, lighting/audio engineers, and safety officers may be consulted as needed during certain QA steps, but the above roles have primary responsibility for QA/QC sign-offs.)
Visual Quality and Theme Fidelity Under Studio Lighting
Ensuring the visual appeal and thematic accuracy of the set under intense studio lighting is paramount. Themed elements must faithfully represent the design concept and brand, even under bright lights and camera exposure. Key procedures include:
Reference Alignment: During fabrication, use design drawings, concept art, and material samples to guide construction and finishing. Document approved color palettes, textures, logos, and thematic details. All artisans and painters should work from these references to maintain consistency.
Studio Lighting Simulation: Prior to final approval, simulate studio lighting conditions (approximately 5600K color temperature is standard for broadcast studios). Use high-CRI (Color Rendering Index) lights at similar brightness to the actual studio to illuminate sample sections of the set. Verify that colors appear as intended and that themed graphics or artwork are not washed out or color-shifted by the lights. If the set will be seen on camera, consider doing camera tests at this stage to see how it looks through the lens.
Glare and Reflection Checks: Under the simulated lighting, identify any surfaces that cause harsh glare or reflections which could distract viewers or obscure the dealers. Matte finishes or anti-glare coatings should be used on glossy surfaces to minimize specular reflections. Adjust angles of glass or acrylic panels (e.g. on gaming tables or displays) to avoid direct reflections into cameras. This ensures the visual fidelity of the theme is maintained without unintended bright spots or glare.
Theme Fidelity Review: Conduct a detailed visual inspection comparing the fabricated set pieces to the design intent. This includes checking that colors, patterns, and thematic motifs are correctly applied and aligned. Under studio lights, the set should look identical to the intended casino theme (e.g. matching branded color schemes, decorative styles) and maintain continuity across all elements. In live dealer studios across different locations, consistency is key – the design format is often replicated and must look identical in each place. Any deviations (e.g. paint hue off-tone, wrong logo placement, inconsistent finishes) are recorded and corrected before sign-off.
Photographic Documentation: Take high-resolution photos of key set areas under lighting for the project record. This helps stakeholders (designers, casino brand managers, etc.) to approve that the theme is accurately represented. It also serves as a baseline for comparing after installation that no damage or changes occurred. All approvals of visual quality should be documented in a Theme Fidelity Sign-off Form by the casino’s design or branding representative.
Inspection and Testing Protocols for Fabricated Elements
Each fabricated component of the set must undergo rigorous inspection and testing to verify workmanship, fit, and function. The following protocols apply to major elements such as gaming tables, set backdrops, decorative lighting enclosures, and props:
Dimensional Inspection: Measure critical dimensions of each piece (length, width, height, thickness) and compare against design drawings/tolerances. Gaming tables should meet specified height and playfield size; set walls/backdrops must have correct overall dimensions to fit the studio space. Document measurements in an inspection log. Allowable tolerances (e.g. ±5 mm) should be defined in advance; any deviation beyond that requires correction or formal concession approval.
Build Quality Check: Inspect construction quality—ensure joints are tight, screws or fasteners are secure, and all edges are smooth. No sharp edges or splinters should be present on surfaces where dealers or staff could touch. For weight-bearing set pieces (platforms, stairs, support structures), verify proper assembly (e.g. use of bolts/screws rather than nails, per theater set best practices) and structural integrity. If any moving parts or mechanisms exist (for example, a spinning prize wheel or a mechanized prop), test their operation multiple times to ensure they move smoothly without binding.
Finish and Appearance: Under good lighting (ambient, not just studio lights), scrutinize all visible surfaces for defects. Criteria include: paint and graphics (no peeling, bubbles, or misalignment), fabric upholstery (no tears, consistent pattern alignment, proper tension with no sagging), carpentry (no cracks or warping in wood), and print quality on any signage. Minor touch-ups (paint fixes, polish) should be done at this stage so that the set looks flawless.
Collision Detection / Fit and Assembly Testing: If the set is modular or will be assembled on site, perform a full dry-fit assembly at the fabrication facility. This ensures all pieces mate correctly (for example, backdrop panels align and lock together, table legs attach firmly). Mark or label parts as needed to indicate proper assembly orientation. Disassemble after verifying fit. This rehearsal of assembly helps catch any fabrication errors and also provides a reference for the installation team.
Electrical and Lighting Checks: For any integrated lighting (such as LED strips in a table or marquee lights in the set), test that all fixtures illuminate properly, at the correct color/brightness, and are wired safely. Cable management must be neat and secure—wires should be labeled and bundled, with adequate strain relief. If there are lighting enclosures or decorative light fixtures built into the set, verify they are properly ventilated (to prevent heat build-up) and that lamp changes or maintenance access is possible as per design.
Functional Testing of Interactive Elements: If the show set includes interactive game components (e.g. a roulette wheel, card shuffler integration, or button panels for game show contestants), these should be tested for functionality and reliability. For example, a wheel should spin freely and land randomly without bias (this might involve multiple test spins and ensuring balance). Any electronic game equipment should be tested in accordance with manufacturer guidelines and gaming standards.
Checklist and Sign-off: Use a detailed QA Inspection Checklist to record each check for every element. Each item (dimension check, finish check, electrical test, etc.) should be initialed by the inspector when passed. If any item fails, record the corrective action taken. Once all checks are satisfactory, the fabrication vendor’s QA manager signs off, and optionally a casino representative or third-party inspector also signs to acknowledge the inspection results before shipment.
Durability and Material Performance Standards
Live dealer studios and game show sets operate for long hours and often 24/7, meaning the fabricated elements must withstand high-frequency use and wear. The QA/QC program sets the following durability and performance standards:
Materials Selection: All materials (wood, metal, plastics, fabrics, paint, etc.) should be specified for commercial-grade durability. Use hardwoods or high-quality plywood for heavily used surfaces (e.g. table tops), metal reinforcement for structural frames, and industrial-grade finishes. For example, polyurethane protective coatings can be applied to props and set pieces to protect against wear and impact, ensuring scenic elements withstand constant use. Likewise, fabrics should be abrasion-resistant and ideally stain-resistant.
Surface Durability Tests: Perform basic durability tests on finishes: scratch tests on painted or laminated surfaces (using a fingernail or a coin edge in an inconspicuous area to ensure the finish does not easily scratch off), and drop tests for props (small impact to confirm nothing cracks or chips). If the set involves rolling components (like chairs on casters or sliding doors), cycle them repeatedly to test their longevity. A test like opening/closing a door 50+ times or rolling a chair back and forth can reveal any weak hardware.
Edge and Corner Reinforcement: High-contact areas such as table edges, platform corners, or steps must be reinforced to avoid premature wear. Use metal edge guards or additional coatings if necessary. All fasteners should be lock-tighten or secured so they do not loosen over time with vibration or use. The QA plan should include verifying protective caps or guards are in place (for example, rubber footings on furniture legs to both protect the set piece and the studio floor).
Environmental Tolerance: Studio conditions may involve significant lighting heat and equipment running continuously. Materials should tolerate a range of temperatures (e.g. from a cooled studio overnight to hot lights during operation) without warping or delaminating. If the studio is in a humid climate or subject to HVAC variations, ensure wood is properly sealed to prevent moisture absorption. Also, any plastics or composites used should be rated to not become brittle under cold air conditioning or soft under heat.
Cleaning and Maintenance Considerations: Because sets will be regularly cleaned (dusting, disinfecting, etc.), finishes must resist common cleaning agents. Use non-reactive and durable finishes (for instance, avoid paint that might be stripped by alcohol-based cleaners). QA can include a test of cleaning a sample surface with the intended cleaning solution to ensure no discoloration or finish damage. Provide the casino operations team with any special maintenance instructions (e.g. “wax this surface monthly” or recommended cleaning products) as part of the documentation.
Life Cycle and Replacement Plan: As part of QA/QC documentation, it’s useful to define an expected life span or usage count for critical components. For example, note that a felt playing surface on a card table might last X months under heavy use before refurbishing is needed, or an LED fixture is rated for Y hours. While not strictly part of initial QA, setting these expectations helps operations plan for maintenance. All materials and components should at minimum meet the warranty or durability specs promised (e.g. if a high-wear component has a one-year warranty under 24/7 use, it should be expected to last at least that long).
(By ensuring durability up front, the QA/QC program reduces the risk of mid-production failures. Remember that a live broadcast cannot afford a set piece breaking or looking visibly worn out on camera.)
Safety and Fire-Retardant Compliance
Safety is non-negotiable in a casino and studio environment. All fabricated elements must comply with fire codes, building codes, and general safety best practices:
Fire-Retardant Materials: All scenic materials must be properly flame-retardant or non-combustible. Fabrics, curtains, or scrims used in backdrops or decorative elements must meet NFPA 701 flame propagation tests for textiles.
Obtain certificates from manufacturers for any drapery or fabric indicating it is flame retardant (FR) or inherently flame retardant (IFR). Wood products (if not naturally fire-resistant) should be treated with flame-retardant coatings or paints if they will be exposed. Large foam or plastic pieces (often used in theme props) are generally discouraged unless specifically formulated to be flame-resistant; if used, they must comply with NFPA 101 and local code requirements for foam plastics.Interior Finish Ratings: Permanent set installations should comply with interior finish class requirements as if they were part of the building, especially if the studio is within a public-access facility. Typically, Class A or Class B interior finish materials are required for assembly occupancies like casinos or studios with significant occupant load.
This means using materials with low flame-spread and smoke development indices (per ASTM E84 testing). Document the flame spread rating of wall panels, set pieces, etc. If any element does not meet Class A/B, ensure the exception is permitted (for example, sometimes Class C is allowed in sprinkled buildings for certain areas, but this should be confirmed with the local fire code).
Electrical Safety: All electrical components incorporated into the set must be UL-listed or equivalent (NRTL certified) for their intended use. According to OSHA and UL guidelines, any product that plugs into an AC outlet must be certified to the applicable UL standard.
This applies to LED power supplies, light fixtures, display monitors, etc., that are part of the set. Cables and wiring must use proper gauge and insulation, and if running through set pieces, cable paths should prevent chafing or heat build-up (for example, use grommets when passing wires through wood). An electrical safety inspection should verify there are no exposed live wires, that grounding is properly done, and that all circuits are not overloaded.Structural Safety and Stability: The set must be stable and secure once installed. Any tall backdrop or wall should be rigidly anchored (to the floor, ceiling, or support frame) or base-weighted to prevent tipping. If the set is intended to be reconfigurable, quick-release locks or latches should securely hold segments together with no wobble. Perform a tip test or push test on set pieces: applying moderate force to ensure they do not tip or slide in an unsafe manner. Platforms or risers must support the weight of dealers, hosts, and equipment with an ample safety margin (at least 4x the expected load is a common rule). A safety officer or building inspector, if available, should review the set installation for any obvious hazards.
Ingress/Egress and Emergency Considerations: Ensure the set layout does not block emergency exits, fire alarms, or sprinkler heads. There should be clear pathways for staff to exit the stage quickly if needed. If the studio has fire sprinklers, tall set pieces should not impede their coverage; many local fire codes require a gap between the top of scenery and the ceiling (e.g. at least 18 inches below sprinklers, per NFPA 13 guidelines). Verify that no part of the set introduces a new fire hazard (for instance, avoid enclosing electrical equipment in a way that can overheat without ventilation).
Fire Extinguishing and Suppression: If any special effects or electrical equipment are part of the set (e.g. fog machines, lots of wiring), ensure appropriate fire extinguishers (of the correct class) are nearby as required. While this is more of an operational safety measure, the set design should accommodate this (e.g. maybe a small recess to hold a fire extinguisher or clear space where one can be accessed).
Sign-off by Fire Safety Officer: Prior to broadcast use, coordinate an inspection by the venue’s fire marshal or safety officer. They will check that materials have the required flame certificates and that the installation is safe. Document their approval or any conditions (some jurisdictions might require periodic flame-proofing renewal for fabrics, etc.). The compliance team should keep a file of all fire safety documents (certificates, inspection reports) as part of the QA/QC record.
Audio/Visual Considerations in Set Design
The QA/QC program must account for factors that affect broadcast audio and video quality, beyond just appearance. The set should be designed and tested to minimize any negative impacts on sound and camera systems:
Minimizing Reflective Glare. Bright studio lighting can cause glare on certain materials, which not only distracts the audience but can also interfere with camera exposure. To combat this:
Favor matte or low-gloss finishes on large surfaces. For example, if the gaming table has a protective glass cover for an LCD display, ensure it has an anti-reflective coating or use etched glass. Likewise, glossy paint should be top-coated with matte clear or replaced with satin finishes as needed.
Position and shield light sources to avoid reflecting into camera positions. During the pre-broadcast lighting focus, have the lighting director shine lights at the set and adjust angles or add diffusers/barn doors to cut down reflections off the set’s shiny elements.
Use of polarizing filters on camera lenses can mitigate remaining glare, but it's better to address it at the source via set material choices. The enterprise broadcasting guide suggests using matte surfaces and adjusting lighting angles to reduce reflections.
These principles should be verified by inspecting the on-camera feed for any hotspots. Any problematic panel might be resurfaced or covered with anti-glare film as a corrective action in QA.
Noise and Acoustics (Set Noise Control)
In a live dealer broadcast, clear audio is essential – background noise from the set itself must be minimized. Consider the following in QA/QC:
Mechanical Noise: Any moving parts on the set should operate quietly. Lubricate wheel bearings, hinges, or motors to eliminate squeaks. If a prop has an internal motor (say, a rotating sign), measure the noise level it produces and ensure it’s below an acceptable threshold (e.g. not picked up by microphones). Replace noisy components or add dampening mounts if necessary.
Set Piece Rattle/Vibration: With the studio sound system (speakers/subwoofers) on, or when people walk on a platform, listen for rattles or vibrations in the set. Tighten loose panels and add foam or rubber padding at contact points. Soundproofing is critical in studios; even though our set is not a full room, any part of it that can resonate should be treated. For example, hollow cavities in scenic elements can be lined with acoustic foam to deaden echo.
Acoustic Treatment: While the SOP is focused on fabrication, it’s worth noting if the design calls for any acoustic panels or curtains as part of the set. Ensure any such panels are installed correctly and meet the NRC (Noise Reduction Coefficient) specified. Even decorative fabric backdrops can double as sound-absorbers if made of thick, heavy material – verify the correct material is used. The end goal is that the set does not create additional reverberation. During pre-broadcast tests, have a microphone live and have staff simulate typical movements (dealers handling chips or cards, hosts walking) to see if any unwanted noise is introduced by the set (e.g. chips sounding too loud on the table surface). Mitigation can include adding a sound-dampening layer under the table felt or using rubber tips on prop weapons, etc., if it's a themed game show.
Equipment Interference and Broadcast Compatibility
The set and its components should not interfere with cameras, microphones, or other production equipment:
Camera Line-of-Sight: Ensure that camera shots are not inadvertently obstructed by set pieces. All critical camera angles (as defined by the director) should be tested with the set in place. If a decorative element blocks a view of the dealer’s hands or the gaming action, it may need to be repositioned or made transparent (e.g. use acrylic instead of opaque material, if allowable by design). Mark floor positions for tables and cameras to maintain this alignment.
Lighting Flicker and Video Sync: All lights in the set (practical lights that appear on camera, like decorative lamps, as well as off-camera studio lights) must be flicker-free for broadcast. LED lights or screens with improper drivers can cause rolling bands or flicker in camera footage. Use broadcast-grade lighting instruments where possible. Flicker-free LED drivers should be specified; this avoids artifacts in the image capture.
A test using a camera at various shutter speeds can confirm no flicker or strobe effect. If any flicker is observed, QA should replace the offending fixture or driver with a higher-quality unit. (Note: This also overlaps with FCC compliance – poorly designed LED drivers can emit RF noise.)Electronic Interference (EMI/RFI): The set should not contain materials or devices that introduce interference to audio/video. For instance, avoid using non-shielded motors or transformers near microphones (they can cause hum). If the set includes wireless devices (RF microphones, wireless video transmitters embedded in props, etc.), ensure they operate on legal frequencies and are FCC compliant. All intentional radiators should have FCC certification stickers. Even unintentional radiators (like LED lights and digital electronics) fall under FCC Part 15 rules, which aim to prevent devices from interfering with each other.
As part of QA, verify that any electronic component has the FCC Part 15 mark or equivalent. Also perform a simple interference test: turn on all set electronics and have audio/video techs monitor for any noise or signal issues (such as a buzz in audio or drop in wireless signal quality). Use ferrite chokes on cables or re-route wiring if needed to eliminate interference.Preventing Production Equipment Obstructions: Plan for where production equipment will be and ensure the set accommodates it. For example, if ceiling-mounted cameras or lights move, make sure the set pieces are positioned so as not to collide. Any stage lighting hidden in "lighting enclosures" (themed housings) on the set must have proper ventilation and not cause magnetic interference to cameras. Also ensure no highly reflective surfaces inadvertently reflect green-screen or studio monitors in a way that could cause visual artifacts.
Audio Isolation: If multiple live game tables/sets are in one studio room, the set design might include dividers or sound barriers. These should be inspected to ensure they indeed reduce sound spill (e.g. use sound-tested partitions). Even for a single set, check that the set doesn’t create a “flutter echo” or weird acoustic by reflecting sound between parallel surfaces. If so, consider adding angled panels or diffusers (as long as they fit the theme). The goal is for the set to sound neutral so that the only audio picked up is the intentional audio (dealer’s voice, game sounds) and not an echo or noise.
Alignment with Gaming and Broadcast Standards
The themed studio set must align with all relevant industry standards to ensure fairness, security, and regulatory compliance:
Gaming Standards (GLI and Regulatory Compliance): Even though the set is largely aesthetic, it can impact game integrity. Follow Gaming Laboratories International (GLI) guidelines where applicable. For example, GLI-19 Appendix C.6 provides requirements on the live game environment security, surveillance, recording, and equipment.
Our QA program should verify that the set design does not hinder compliance with these requirements. Surveillance cameras must have clear views of all gaming surfaces – ensure no part of the theme decor blocks a top-down view of cards or the roulette wheel, etc. The environment should be clearly demarcated as a secure gaming area, meaning our set should not inadvertently create hidden areas that staff or extraneous objects could be concealed in. If the gaming commission or regulators require any physical features (for instance, a specific layout of the table or placement of discard trays, dealing shoes, shufflers, etc.), verify those are present and correctly installed.Fair Play and Security: QA/QC should include checks that nothing about the fabrication could be used to cheat or tamper with the game. For example, tables should have no concealed compartments where extra cards or dice could be hidden. If using mirrors or reflective surfaces as part of décor, ensure they cannot be angled to give unauthorized views of cards. Any electronics used (like an automatic card shoe or wheel sensor) should be the certified units approved for gaming and installed per the manufacturer and regulator’s instructions. Compliance officers may do a walkthrough to confirm that from a regulatory perspective the set does not introduce any issues (like marked cards due to reflective table, etc.). All such concerns must be addressed before going live.
Broadcast Standards (FCC, etc.): All broadcasting equipment in the studio (cameras, microphones, transmitters) will be subject to FCC rules, but the set itself should not push anything out of compliance. We have already covered Part 15 interference concerns. Additionally, ensure any video displays on set (like if a game show has a screen for scores or a slot-machine simulation) comply with broadcast standards for content resolution and do not flicker on camera. If the production is for TV, ensure that any lighting intensity or patterns used on set do not violate broadcast regulations (for instance, very intense strobe lights could violate some safety guidelines for viewers with epilepsy, though that’s more content than set fabrication – but if relevant, include a note to avoid rapid flashing set lights).
Local Building Codes: Treat the set as an interior installation that might require building code compliance. Consult with local building code for stages/sets – for example, in some jurisdictions a large constructed set might need a temporary structure permit if it’s significantly large or occupied. Ensure load-bearing elements (like an overhead theme prop hung from the ceiling) are installed with rated rigging hardware and perhaps inspected by a licensed rigger or engineer. If the casino property requires it, get an engineer’s sign-off on any custom structural element. All glass used should be safety glass (laminated or tempered) if there’s any chance of breakage near people. Compliance teams should check these against OSHA or local occupational safety requirements as well if staff will interact closely with these elements.
Ergonomics and Operator Safety: While not a formal “standard,” aligning with best practices for dealer comfort and safety is important (and often scrutinized by regulators for fair working conditions). The table height, chair design, and space behind the table should all follow ergonomic guidelines. QA/QC can verify that, for instance, there are no awkward sharp corners where a dealer sits (to prevent injury or uniform snagging), and that there's sufficient knee space under tables. This also aligns with ensuring smooth operations – a more comfortable dealer will perform better, reducing errors on air.