We have a job that requires a 22 foot wide blackout shade. The client does not want to use drapes, and wants complete blackout. They don't want to break up the shades into more than one whole shade. This would require side rails and a 22 foot wide shade by about 10 feet high in side rails.

Has anyone ever done this before?

Thanks.

I've never done one that wide.  If you're a Lutron dealer, you can inquire with them... they do custom shades in larger dimensions than you can specify with the shade configuration tools.

I took over a job where two blackout roller shades were stacked side-by-side in a tall recessed pocket.  The two shades were overlapped by about 12-14" where they met in the center and then the left and right edges were in side channels.

I'd never seen this done before, but it worked and had been working for 5-6 years.

If you do find a way to do a single shade, I don't think you'll find fabric that wide so fabric would need to be railroaded.  Since the shade is only 10ft tall, you might be able to use the fabric horizontally without any "railroad" seems.

Ask if they want seams- if they say No, tell them it's not possible- even sails have seams. Fabric comes in certain widths and they don't like changing that. It's probably possible to get wider fabric, but the shade's motor will never be able to handle the weight unless you can find a projector screen that would work,

If you could even get fabric that wide it would smiley face ripple. But you cant get one that wide so that wont be a problem.

You should look into something like this [Link: smartglassinternational.com]

Or this, if they just want to add it to their existing windows-

[Link: raynofilm.com]

If you look at companies like Da lite, they can make projection screens over 20ft wide, so I would have to think getting a black out roll shade is possible.
Going to be on a very large tube and require a lot more effort to install than your typical shade.
We did a Stewart screen in a theatre that was around 19ft wide. Took 4 guys to move it and install.

I needed a 12 foot one for my theater. I made my own. In hindsight, I should have broken it up into multiple shades. The roller (steel EMT) sags the smallest amount towards the middle causing the fabric to have slight wrinkles in the corners.

call an experienced local somfy dealer

We suggested motorized drapes but the designed does not want drapes. We suggested creating a pocket to hide the drapes so you cannot see them but still no go.

And how often will the designer be there after the project is done?

Exactly.

Check out US Motions/Universal Screen.

[Link: keoutdoordesign.com]
Not sure if this company could fabricate the width you need but, I am doing a custom install of this product to enclose an outdoor kitchen with see through vinyl for a client.
They claim they have 500 materials (assuming they would have black out fabric) to choose from and the guide system can be recessed into the wall, which is what we are doing into some massive cedar trimmed posts that support the pergola.
I have not seen the product in person yet but, we will have the install completed by Easter for our client.

I don't know if it can be made more quiet, but the exterior awnings use an extruded aluminum tube that would definitely hold the weight of blackout shades without sagging. The diameter is much larger than the usual for shades, but it would be similar to what is used in the link for the Italian company.

I just saw that future automation is offering shading now! Maybe take a look at them and see what they could come up with?