How Bavari Created the Perfect Curved Concrete Stairs Using FlexJet's 3D Measuring System

Here at Bavari, we are always trying to increase our efficiency and improve our accuracy and excellence in workmanship, which is why we are very excited about one of our more recent pieces of technology – the FLEXIJET 3D!

This machine is fast, precise and highly flexible – perfect for our line of work – measuring off standard rooms and in this case curved concrete staircases. Adding this little piece of highly intelligent equipment to our already top-of-the-range machinery & software greatly increases our job opportunities and sets us apart when it comes to accuracy and efficiency for precise, complicated and top-quality jobs.

The Custom Stairs Challenge

One of our recent completed projects was based in Wimbledon, London included 3 curved concrete staircases stacked on top of each other to be clad with timber strings, risers, treads & handrails. These curved stairs were not working off a true radius & because of the substantial variation in shapes & inaccuracies in the rises, meaning each stair would have been extremely difficult to measure. Even with laser technology, there would have been weeks of taking templates, checking, tweaking and re-checking.

The clients and their architect had great ideas about how they wanted the stairs, and in particular the handrails, to look. They liked volutes on every floor, but also wanted to connect the handrail continuously from the basement all the way to the 2nd-floor balcony.

Our Work

Now, anybody who knows us will know that we love a challenge and are extremely particular with the quality of work that we put out.

For us, this project ticked every box:

• Custom Stairs Design

• Top quality

• Intricate & Detailed Work.

Following an initial site visit where draft 3D drawings were created, quotations were provided, and the order was placed, the Bavari team set off to effectively utilize our Flexijet 3D. We successfully gathered all necessary measurements for the bases of three concrete staircases.

These measurements were then meticulously converted into a comprehensive set of working drawings, complete with 3D renderings, utilising our advanced software and CAD/CAM systems. Subsequently, we commenced the manufacturing of the three curved staircases.

Upon completion, four installers travelled to London to oversee the on-site delivery of the staircases. Remarkably, within just five days, all three staircase structures—including strings, treads, and risers—were installed alongside metal spindles and curved balconies, fitting seamlessly onto the existing concrete stairs with minimal adjustments. Additional trips were required to install the intricate handrails and to apply the staining, lacquer, and final touches, culminating in a stunning end result.

We extend our gratitude to everyone involved, especially our wonderful clients and the supportive team on site; it was a pleasure collaborating with you on this project!