Fabricating your custom monumental stair at Equus Metals begins with a seasoned team of detailing and drafting personnel. We sub-contract engineering services and have worked with several companies for many years to provide a complete engineering report for our monumental stairs and ornamental railing systems. It should be noted that as much as is feasible, all Equus Metals systems are fabricated complete in our shop, disassembled and packaged for shipment, thereby assuring a well-built, correctly-fitting end product. Once Drafting & Engineering has been completed, and the drawings sent to the shop for fabrication, the process is generally as follows:
Level balcony handrails, inclined ramp rails, or rail systems installed on pre-existing stairs are fabricated in much the same way as Equus Metals’ stair rails are, with the exception that the glass is normally mounted in an aluminum extrusion, or a steel fabricated “shoe”. This “shoe” is an Equus Metals’ furnished product also
Once the rails and/or stair is built and welded complete, they are disassembled for shipment, and sent to the finishing department where the welds and any blemishes in the material are removed. The individual pieces are then wrapped, or packaged accordingly for shipment.
The stairs are then prepped for the particular finish they are to receive. If they are to be a painted stair, all welds are ground smooth, the entire system is sandblasted, then prime painted. If they receive a “clad” finish of brass, stainless steel, or ACM panels, the stringers are “dressed down” with grinders, and prime painted prior to the covering being installed.
The handrail material is then shaped, fitted to the stair, and welded together. The handrail is built directly on the stair to insure a reliable and proper fit before it is shipped to the job site for installation. The rails can be fabricated from a variety of materials including brass, stainless steel, wood, painted carbon steel, aluminum, and in a variety of final finishes from “mill” to “mirror”, and in a myriad of configurations, incorporating either glass or “picket & post” design.
A plan view of the stair is laid out on a steel plate floor, showing beginning and ending points of the steel, along with any break-over points, and points-of-reference for aligning the individual pieces of steel.
Keep in mind that a box-style stringer for a curved stair must form the desired radius all the while gaining height in rake. For some projects, we can simply “twist” a tube. But in many cases, Equus Metals will fabricate the box stringer from plate steel. Shapes are drawn out on a sheet of steel and cut to shape. The inside and outside of the stringer are then rolled to create the radius. The top and bottom of the stringer are crescent shaped to match the radius, and then the entire stringer is welded up to specifications. Any miscellaneous braking of the steel plates and angles for the stair are fabricated, including any “hardway” bent items, bent treads and risers, etc.