Together with the customer’s design team the Brass Workshop worked on the design of a brass balustrade for three flights of stairs and two window apertures. We manufactured 64 brass baluster assemblies in our shop, each comprised of a shaped and a straight part. The fancy part took a lot of machining: cutting, milling, lathing, welding, riveting and polishing. The brass baluster heels were their own challenge, what with their nuanced pyramidal shape and open-end apertures. We manufactured 128 of those.
But the brass handrail was arguably the biggest challenge of the project, particularly the bends and the curves toward the wall and the floor. The handrail strip had a cross-section of 60mmх20mm – quite a tall order to cut and bend.
The design envisaged a seamless brass handrail with flawless curves between the straight sections. In order to achieve a precise three-dimensional bend on the transitional sections, first we joined the straight handrail sections by means of templates, then used the templates to manufacture conductor boxes in which the curvilinear sections were heated up, assuming the necessary shape. The balustrade sections were welded together onsite and the joints brushed into invisibility. The handrail looks like a solid bar of brass now.
When installed, the balustrade was treated with a protective coat to assure the longevity of its excellent look and the great job we did! We wish our customer long years of happy life in their new residence!