[{"id":"096d89ca-cad9-4dda-80ef-99b94cb5768f","cells":[{"id":"073b73bf-eb7d-497a-baf0-c78557a393cb","inline":null,"size":12,"rows":[{"id":"2bf2b4f2-d6b3-408e-9ad8-80fe74208f76","cells":[{"id":"8508cac8-fa03-499b-bf40-ed59afaee54a","inline":null,"size":12,"layout":{"plugin":{"name":"peracto/layout/container","version":"1.0.0"},"state":{}},"rows":[{"id":"40568a0a-aea6-44eb-997c-62c225bab79b","cells":[{"id":"c9f7506d-de3e-4847-bbb2-79cc8808a238","inline":null,"size":12,"content":{"plugin":{"name":"peracto/content/text","version":"1.0.0"},"state":{"text":"

Making a bespoke metal staircase

Dallas Burston Polo Club is an award-winning events venue nestled in the Warwickshire Countryside, offering guests a choice of four stunning venues across a 600-acre site. They required an impressive bespoke feature metal staircase and gallery ballustrade for their venue; this is the story of how we made it.

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Enquiry - site survey - drawings - sign off

After the initial enquiry and preliminary technical design consultation, we visited the Polo Club to undertake a site survey. This is standard procedure with all of our metalwork enquiries after the terms have been agreed upon. A site survey helps to pre-empt any installation challenges and ensure that what we are going to make will fit exactly where the client wants it to go!

Our in-house CAD design team then worked with AT Architecture and Dallas Burston Polo Club to produce detailed plans and elevations. The technical drawing on the left is just one of the arrangement drawings created for the project.

When everything was approved we then began to fully manufacture and assemble the metal staircase in our workshops.

Manufacturing the metal staircase and gallery ballustrade

The steps themselves were fabricated from 3 mm thick steel sheet and folded into shape using a sheet metal folder.The staircase has a subframe and each individual step is mechanically fixed to this with nuts and set screws. Decorative balusters and panels were then added, before we took it all apart again!

Large bespoke structures are usually assembled to completion before being dismantled for finishing because it allows us to ensure our structures are constructed and finished to the very highest standards, whilst minimising the amount of time required on site.

This staircase was fabricated and assembled in the workshop prior to being dismantled, it was then sent out to have a coat of fire-retardant powder-coated paint applied. Once it returned from the painters it was shipped to site in individual elements on one of our wagons.

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Decorative metal balustrade panels

The decorative balustrade panels to the stairwell and void feature laser-cut mild steel panels in a circle motif with decorative cast rosettes in the centre. The large panels were laser cut from a 10 mm thick mild steel sheet then ‘rolled’ individually to achieve the exact curvature required for each section, once rolled to the correct profile they were then finished in a dark gunmetal powder coat.

The handrail was fabricated from a solid brass flat bar, again rolled to exactly match the shape of the metal panels.

We can make completely bespoke structures to whatever visuals you have in mind, but we also have a range of metal castings on our website which can either be incorporated into your structure or simply browsed for inspiration.

Installing the metal staircase on site

Three members of our metalwork team were on site for a week to assemble and install the whole structure from its separate painted components.

On large-scale projects, we provide a complete turnkey management service; our project managers ensure the work is well-coordinated throughout the manufacturing and site installation process so it's completed on time. You'll also notice the broom to the side of the photos - because we always tidy up after we're done!

View more metal staircases here or get in touch to discuss a specific project.

Making a metal staircase for Dallas Burston Polo Club

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