Custom Fabrications was commissioned to install a new four-storey internal staircase at Paragon Mill, a Grade 2 listed conversion in the Ancoats area of Manchester.
The building
As an iconic heritage building, Paragon Mills is steeped in history. When it was built in 1912 the eight storey mill became the world’s tallest structure. Paragon Mill is the final mill conversion phase of the Royal Mills Development.
The brief
Custom Fabrications was asked to design an internal staircase that would be authentic to the history of the mill, using industrial style materials that would complement the interior exposed brickwork and muted tones of the décor. Before beginning the installation, we were asked to remove the 1990’s pine staircase that had been installed when the mill was originally converted.
The new 4 storey staircase was to be installed in the former lift shaft of the penthouse apartment. As with all heritage projects, we approached the design and installation with great sensitivity to protect the structural integrity of the building.
Challenges
Working within a Grade 2 listed building presented us with several project challenges.
• There were only two ways we could access the property; using the small 6-person lift or climbing 6 flights of stairs.
• To protect the building we were unable to attach the staircase to any of the walls.
• As is typical with buildings of a certain age, none of the floors were straight or level.
• When we lifted the floor for the first time, after all designs had been signed off, we discovered that the pressurised fire suppression system ran directly through where we needed to install the base of the staircase.
All these challenges extended our anticipated timescales, and changed the way we built the staircase. As all components could only be transported to the penthouse apartment using the small lift, we needed to design the staircase in small sections so that it could all be moved. Over 4 storeys this was physically difficult and time-consuming to do.
Our solutions
The Custom Fabrications team approaches problem-solving straight on, with a can-do approach. As we always say: "Whether it’s custom staircases, railings, gates, or metal furniture, we thrive on answering “Can we do this?” with a confident and resounding “Yes.”’
This was no different when it came to getting the staircase in place. Using our knowledge and expertise, we designed a new jigsaw-type modular system. Once all individual sections were transported to site we were able to slot them into place and then weld them for additional strength.
To achieve the required industrial/contemporary aesthetic balance, we incorporated a range of materials into the design, including reclaimed timber, mild steel (low carbon steel) and Banker architectural mesh with a brushed brass finish that took 13 weeks to arrive from the US.
Reclaimed wooden treads from Kings Cross Station were installed as a sustainable and authentic solution. The mild steel was used for the frames while the architectural mesh was adapted to create unique gauze-like, transparent panels that allow the light to filter through. We lined up the pattern on the mesh so wherever you look through it, the patten correlates throughout.
For the handrail, we decided upon a bespoke Clive Durose walnut handrail. Due to the lack of straight lines in the building, we needed to forge the handrail steel guide in our workshop for the Clive Durose team to map. This ensured that we had a perfectly curved rail over the 4 floors.
Outcomes
We produced a beautifully crafted, high-end industrial style staircase with soft tones that is ideal for penthouse living. The staircase has a clean lines appearance without visible welds or fixing points.
The staircase floats from the wall instead of being fixed in order to meet the specifications of listed buildings.
We were delighted to have found a solution to the fire suppression system without having to change much of the overall design.
The client now has a practical and sustainable, yet architecturally stunning, staircase that is a main feature of the property.
Are you specifying architectural metalwork for an upcoming project?
Custom Fabrications is a boutique but cost-effective architectural metalwork business based in Stoke-on-Trent. We create bespoke metalwork solutions including railings for staircases, balustrades, gates and bespoke metal furniture for projects of all sizes. We use both traditional and modern techniques to create superior bespoke metalwork solutions.
Contact us on 07498 328 921 or email info@custom-fab.co.uk to find out how we can help with your project.
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