When we were asked by Tadhg O’Driscoll Design to look at the possibility of manufacturing a stunning cantilevered staircase in conjunction with Henry J Lyons Architects for Kennedy Wilson’s new offices we just had to check it out.
Cantilever design with fixings only at the top and bottom using mildsteel, glass and stainless steel and of course our blackwash finish to the metalwork. This was always going to be a challenge but a challenge we were ready to take on. The Main Contractors on this were Flynn who proved very helpful during the install process. Having all parties involved working together is always critical to executing an install correctly.
We set about preparing our working drawings in our design office in Ballyfoyle, Co. Kilkenny and working with Michael Punch & Partners Structural Engineers we got our design detailed, approved and then ready for production in our metal fabrication facility.
Advance Steel working drawing complete
Fabrication commenced. With over 10 tonnes of steel being placed in the support frame alone this was a complicated piece. Joint preparation was critical to this project due to the structural engineering requirements.
Center spine almost complete
Fabrication underway of the staircase structure.
Weld tests were then carried out to ensure the quality of the fabrication process. Non destructive magnetic particle testing was acceptable in this case………. All welds passed!
Weld testing taking place
The Staircase was then loaded onto our truck and transported to site in the early hours. Due to a tight program the staircase core was lifted by crane in through the roof of the building.
Delivery from our factory in Ballyfoyle, Co. Kilkenny
Lifting the staircase into position through the roof opening
Our site crews got to work and the Staircase Structure was installed. Working to a tolerance of plus or minus 3mm so the other elements can fit correctly.
Centre spine being installed
In the meantime our fabrication crews get working on the feature balustrades back on the factory floor
Mildsteel panels being fabricated
Some complicated shapes being assembled
Once fabricated the panel installation process begins on site
Panels get installed on site
almost complete
We then began the glass install. 6.5 tonnes of glass were delivered to site and all installed carefully on the prepared structure.
Curved glass being fitted. These shapes were taken straight from our drawing without templetes. That is the level of trust we place in our team.
Curved glass on the half landings
Once the heavy metalwork is complete we moved onto the finishing touches.
The finishing touches commence
The electricians get working on the lights
48mm diameter stainless steel tubular handrails were installed with mitred, welded and poished welds. Due to the complicated shapes on this feature staircase we did have a requirement to site weld many joints.
The finished piece.
This is just another architectural metalwork package designed, fabricated and installed by our dedicated team of skilled metal fabricators who really love a challenge.
Please feel free to contact us to discuss this and other projects that you may have queries on.