Iron staircases are typically made through a combination of design, cutting, shaping, welding, and finishing processes. Here’s an overview of how they are made:
- Design & Planning
Blueprint/Design Creation: The process begins with designing the staircase, which includes calculating the dimensions (such as the rise, run, angle, and overall size). A CAD (computer-aided design) model is often created to provide detailed specifications.
Material Selection: The type of iron (cast iron, wrought iron, or steel) is chosen based on the staircase’s design, load requirements, and aesthetics.
- Material Preparation
Cutting: Iron plates, tubes, or bars are cut to size using metal saws or CNC plasma/laser cutting machines. This creates the basic components, such as treads (steps), risers, stringers (the sloped parts), balusters (support columns), and handrails.
Shaping: The components may need further shaping. For curved staircases, iron is bent using heat or mechanical rollers to match the design specifications.
- Assembly
Welding: The staircase parts are assembled by welding, where heat is used to fuse iron pieces together. Welders work to join the treads, risers, stringers, and other elements.
Bolting: In some designs, parts of the staircase are bolted together instead of welded, especially if the staircase needs to be modular or adjustable.
- Finishing & Surface Treatment
Grinding & Polishing: Welds and other imperfections are smoothed out using grinders and polishing tools to create a clean surface.
Coating: Iron staircases are often painted, powder-coated, or galvanized to protect against rust and corrosion. Decorative finishes like patinas or ornamental designs can be applied to enhance aesthetics.
- Installation
Once the staircase is complete, it is transported to the site and installed. This may involve anchoring it to floors, walls, or support beams. Final touches, such as handrails and decorative elements, are added during installation.
This process results in a durable and visually appealing iron staircase, whether for residential, commercial, or industrial use.