A Cheshire property owner appointed Custom Fabrications to manufacture and install a bespoke balustrade for an existing staircase.
The brief
The brief for this project was to design and fabricate a bespoke metal balustrade for a wooden staircase in a residential, period property.
We were to replace just the balustrade, and work with the existing staircase, leaving no visible welds or fixing points to ensure a clean finish.
Our work was part of a full renovation project which was midway through completion when we arrived on site. We needed to collaborate with other contractors and meet a tight schedule to get our work done at the appropriate time and keep the project on track.
Challenges
The existing staircase was a wooden structure, with typical quirks of its time. It was a space-saving U-shaped design staircase with two platforms, three different angles and no square or parallel components. The three stringers (structural boards that provide the framework for the treads and risers) were positioned at different angles.
To accommodate the directive to leave no welds or fixing points, we decided to manufacture the balustrade in two separate pieces. This meant additional welding on site to perfect the installation. A tight hallway and landing area provided little space and made it difficult to manoeuvre the two main sections into place.
Because the property was undergoing a full renovation, we needed to be particularly agile and flexible in our approach to this project. Juggling timescales and windows of opportunity was necessary for ensuring the project ran smoothly. We will always work with our clients and other contractors to achieve shared goals and ensure client satisfaction, so this was a challenge but never a problem we couldn’t overcome!
The client commented:
From the initial consultation, measuring and design meetings with Dan, to the meticulous fitting of our amazing balustrade, Custom Fabrications have been truly wonderful. Their creativity and ability to tackle tricky spaces and design challenges has been a joy to be part of, and nothing has been too much trouble!
This beautiful design and bespoke finish suits our space perfectly! We are in love with our new staircase and the envy of our neighbours!
Our solutions
We designed the balustrade to be made with black powder coated mild steel. Powder coating provides durability and corrosion resistance. It has become a popular choice due to its visual appeal and the attractive finishes it creates on metalwork features in both residential and commercial properties.
In this property, the black powder coated balustrade and panel on the landing provided a dramatic contrast to the neutral carpet and white walls and woodwork. This made the staircase the focal point of the hallway, even though it was almost tucked away to the side of the front door.
Mild steel was chosen because it can be reshaped and manipulated without losing its rigidity. Also known as carbon steel due to its much lower carbon content, mild steel is also a more cost-effective and environmentally friendly alternative to structural steel. Steel is a very straight, unyielding material to work with, so to overcome the structural challenges we made significant alterations to the wood. We also handcrafted all the spindles to different sizes to match the vertical lines throughout.
Given the potential pitfalls of the structural challenges, we used laser levels to achieve pinpoint accuracy. The powerful laser beam can cut through steel with maximum precision.
We undertook many site visits before the installation started to ensure a perfect finish.
Outcomes
We are known for our problem solving skills, and thrive in an environment where it is essential to think outside the box. Using our knowledge and expertise, we provided a stunning aesthetic and robust solution to an irregularly configured staircase.
The finished powder coated steel balustrade is a striking feature of the hallway. As requested, there are zero welds or fixing points visible.
We were delighted with the client’s reaction to our finished balustrade and their appreciation of the way we approached the project and met the brief, despite the many challenges we faced.
For bespoke metalwork solutions for residential or commercial projects speak to Custom Fabrications
Call us on 07498 328921 or email info@custom-fab.co.uk for more information about our services.