Custom Fabrications were commissioned by the owner of Finlow Farm in Mottram, Cheshire to design and install internal and external staircases, a metal wall fire surround, entertainment unit and window surrounds for the prestigious property.
The brief
Custom Fabrications were originally invited to quote for the design and fabrication of a coffee table. During an in-depth, insightful conversation, structural fabrication requirements elsewhere in the property were addressed and commissioned by the owner instead.
The main elements of the project were the internal and external staircases and the huge wall of steel for the chimney breast fire surround. For the internal staircase, the client wanted balustrades with a unique, high end mirror image design.
Challenges
This project was commissioned and completed during the COVID-19 pandemic of 2020 and therefore put on hold several times, so it took considerably longer than expected to complete.
Managing the client’s expectations regarding timescales and the cost of materials was essential, although fortunately the client completely understood and was supportive throughout.
The size of the metal wall for the fire surround made it very difficult to transport without subjecting it to damage. The metal wall was to be transported to
Birmingham for the application of the pewter finish so we needed to be extra vigilant and put strategies in place to protect it.
We had never produced a staircase of this size before, and making the mirror image of the internal staircase balustrade was challenging in the workshop space we had available as we needed to lie the two balustrade structures next to each other during the fabrication process.
The client wanted a spontaneous, rather than repetitive, pattern on the balustrade so we had no specific guidelines for the design. We therefore used our design expertise and took inspiration from our conversations with the client to produce beautifully crafted balustrades that were a mirror image of each other, as requested.
Our solutions
For this project we used mild steel, solid oak steps, anodised treatment, stainless steel and aluminium.
We adapted quickly to the situation regarding rising costs and came up with new, innovative ways to achieve the look the client desired, but at a fraction of the cost.
As an example, the cost of Corten steel had risen dramatically. Also known as weathering steel, Corten steel doesn’t require paint or coating. When exposed to the elements it develops a protective layer resembling rust which makes it highly resistant to corrosion. To overcome the rising cost problem, for the external designs we used a powder coat Corten effect instead of Corten steel.
At Custom Fabrications, we are known for thinking outside the box to solve problems and come up with innovative ideas. This is the environment in which we thrive. We were asked to leave no fixing points visible on the chimney breast wall of steel and for it to be as flush as possible with the render, so we built a new bespoke fixing mechanism for attaching the steel to the wall.
Using our knowledge and expertise we also developed designs that made all of the window surrounds fit the bespoke windows that had been supplied by a third party.
Outcomes
We produced steel fabrication designs with a clean finish that had zero welds and no fixing points visible.
Despite the unavoidable limitations that we faced during the COVID-19 pandemic and having to manage the client’s expectations, we still delivered incredible products and completed the project within a year.
The client was delighted with the products we supplied. They now have a beautiful, architecturally stunning staircase that is a main feature of the property, as well as a unique metal wall fire surround with the required clean finish.
Do you need steel fabrication and welding services for an upcoming project?
Custom Fabrications is highly reputable fabrication and welding business based in Stoke on Trent. Get in touch to find out how our designs can transform internal and external spaces.
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