Case Study
J&M Welding Inc. was contracted by a residential general contractor to design, fabricate, and install a custom interior handrail system for a newly constructed home in Los Osos, CA. The project involved precise coordination with the build timeline and interior finishes, with one unique challenge: the handrail posts needed to be notched into the stair treads, requiring careful planning and execution.
Client
Residential General Contractor
City
Los Osos, CA
Process
1. Client Meeting & Site Walkthrough
Our team met with the general contractor to review design intentions, staircase dimensions, and the homeowner’s aesthetic preferences. It was crucial to understand the timing of flooring installation, as this impacted how the posts would be anchored.
2. On-Site Measurements
Accurate measurements were taken to ensure proper alignment of the post locations with stair geometry. This included precise tread and riser dimensions, spacing for cable rail lines, and accounting for trim and wall clearance.
3. Shop Drawings
We created detailed CAD drawings outlining all components, including mounting plates, post heights, angles, and cable spacings. These were approved before moving into fabrication.
4. Fabrication in the Shop
Handrails were fabricated using square steel tubing for posts and flat bar for the top cap. The parts were TIG welded and prepped for powder coating. Due to the notching requirement, each post had to be customized to match the stair treads exactly.
5. Installation
Our team installed the rail system with careful attention to the pre-notched floors. Each post was fitted securely, and cable lines were tensioned evenly for safety and aesthetics. The final result was a sleek, modern stair rail that blended seamlessly into the home’s contemporary interior.
Challenges
The primary challenge for this project was designing the post mounting system to work with notched wood flooring, which was already installed by the time of the handrail installation. This meant our team had to work with extreme precision to avoid damaging the finish floor while ensuring structural integrity. By customizing each post to match the tread profile, we achieved a clean, flush look that met both safety and design standards.
Final Outcome
The homeowner and general contractor were highly satisfied with the outcome, praising the clean lines, solid construction, and on-time installation. J&M Welding delivered a fully custom, modern solution tailored to the unique construction timeline and architectural requirements.
This image captures the staircase prior to railing installation. The stair structure is fully built with bare wood treads and risers, but no railing is present. The open design and clean walls highlight the need for a modern railing that complements the architectural style. The photo was taken during the home’s construction phase, with floor protection still in place and unfinished details visible.
Inside J&M Welding’s fabrication shop, the steel handrail components are laid out on a welding table. You can see the precision layout of the posts and frame sections, with clamps and tools in use to hold pieces steady during assembly. This image shows the detailed work required to get the geometry right, especially given the custom notching needed for stair mounting.
The final product is fully installed and showcased in this image. A sleek, powder-coated black steel handrail with horizontal cable infill lines the staircase, creating a visually appealing and secure transition between floors. The posts are perfectly aligned, and the railing integrates seamlessly into the notched flooring. Sunlight pouring through the windows enhances the clean lines and modern finish of the completed staircase.