Precast concrete stair flights have been manufactured for years and are an effective way of installing multiple flights in fairly quick succession, this has obvious benefits when dealing with large developments such as office blocks or car parks for example.

Stair Moulds for Traditional Staircases

Timber stair moulds can be made in a variety of ways and the variation is usually dependent on the surface finish of the precast unit at any given point. For example, a mould made for a unit whose soffit is either hidden or subject to a post-installation finish may be poured through the soffit and trowelled smooth giving a high-quality finish to the treads and risers.
Where the soffit is not subject to any treatment once installed it may be the case that the mould be filled on edge, this means that the soffit, treads and risers and one edge of the stair flight will have a high-quality finish with the fact that the concrete was poured through being trowelled to a smooth face.

Stair moulds can also be filled as cast with the soffit being in the base of the mould with the sides carrying the profile of the stair, timber boards are laid between the 2 sides and bolted into position. It is rare for a straight stair mould to be filled in this manner but it can be an option particularly where there might be 4 or 5 steps winding around a corner leading around to a further straight flight.

Stair flights can have landings including either top or bottom, sometimes both and as with a traditional timber mould, change pieces and stop ends can be included to cast variations.

Aside from the more traditional stairs already mentioned, helical staircases can also be produced and there are many ways that these types of moulds can be produced. A truly unique staircase is one way to make your mark. While traditional staircases are functional and designed to fit within the layout of most developments, those afforded with additional space may look to switch up this basic design.

Stair Moulds for Helical Staircases

Helical staircases, or those that twist round into a spiral, are a beautiful and elegant addition in any space. They take up minimal floor space, are generally produced in one piece for easy installation and can still be a safe option. For many, it is the look that takes their breath away and stays the main reason as to why they choose to include this design in their office space or home. Here at 3D Pattern and Mouldmakers Ltd, we produce stair moulds for helical designs regularly. And this blog will explain how they can turn your design into reality.

One of the visual charms of helical staircases is how perfect the spiral looks from a distance. And to achieve this, you need to combine years of expertise with the tools to create components that fit against each other perfectly. Here at 3D Pattern and Mouldmakers LTD, we have worked with many clients to meet their specific needs. Over this time, we have established that the most effective and successful method of creating a helical or winding staircase is by making the mould ‘as cast’. Using a CNC machine, we create the soffit of the mould before machining radial formers for the inner and outer walls which are cut to the profile of the stair, boards across the inner and outer wall are bolted into position and are individual pieces giving the option to progressively pour the stair mould.

Using this advanced technology, we can provide the perfect helical twist. Like a traditional timber mould, the soffit of the stair becomes the base of the mould and will be subject to a high-quality finish, as usually this can become the focal point when the staircase is cast and installed. All other components including sides and ends fit together like a glove, giving the ability to cast a stunning functional piece of precast concrete. Staircases such as these vary so much due to their bespoke nature. Some clients want tightly wound spirals that slot into the most compact spaces while looking elegant. Others are looking for more of a sweeping shape that accommodates wider steps. Achieving both is possible through the use of high-quality, durable and sturdy timber stair moulds.

Designing Your Helical Staircase

As bespoke as your project is, so should your helical staircase mould be too. Working with the right manufacturer, such as our expert team here at 3D Pattern and Mouldmakers LTD, means you’ll be able to talk through complex design requirements. And you’ll be one step closer to bringing the undeniable elegance and eye-catching look that these swirling staircases have to offer within your development.

If you would like more information on how stair moulds can help create your helical staircase, please don’t hesitate to contact a member of our team today.