When Dick’s Sporting Goods prepared to open a new store in Salem, NH, they needed a custom metal staircase and mezzanine that allowed employees and customers to move between floors. The challenge was that the entire structure had to be fully self-supporting, with no vertical posts or beams tying it into the surrounding floors.
The team at Macy Industries worked closely with Dick’s engineers and architects to design, fabricate, and install a floating staircase and mezzanine that met strict OSHA and IBC compliance requirements while delivering the modern, open aesthetic the space demanded.
Engineering a Staircase That Defies Gravity
Most commercial staircases rely on vertical posts or attachments to the ceiling or floor for structural support. For this project, the staircase and mezzanine had to stand entirely on their own, relying solely on engineered connections and structural steel design.
Meeting this requirement called for careful planning, precise engineering, and close coordination across teams.
- The staircase and mezzanine needed to support continuous public foot traffic without flexing or shifting.
- Custom metal handrails had to be mounted directly to floor joists and stair stringers rather than anchored into concrete.
- All components had to meet OSHA and IBC safety codes, from railing heights to stair rise and run dimensions.
Dick’s Sporting Goods brought in an engineer to handle the building’s structural design. Once Macy Industries was engaged, we collaborated with a second engineer to refine and improve the design, ensuring the staircase and mezzanine were structurally sound, code compliant, and built for long-term use.
After six weeks of design refinements, including updated calculations, material adjustments, and load evaluations for a fully occupied staircase, the project was ready to move into fabrication.
Precision Fabrication for Strength and Durability
With the design finalized, our team began transforming raw steel into the components required for a fully functional mezzanine and staircase.
We used our 6-axis CNC plasma cutter to fabricate the custom metal handrails and railing assemblies. Larger structural elements, including stair stringers and the mezzanine framework, were cut using a bandsaw before being prepped for installation.
The fabrication process included:
- Cutting and prepping stair stringers, mezzanine framework, and railings
- Welding and polishing seams for strength and a clean, professional appearance
- Painting components to achieve a durable, finished look
- Packing and transporting all fabricated parts to the job site for staged installation
With all components delivered and staged, the project moved into the most complex phase: installing a floating staircase with no direct floor supports inside an active retail construction environment.
Bringing a Complex Design to Life
Installing a structure of this scale inside a commercial space required careful coordination and specialized equipment. Without vertical posts to anchor the structure, our team used telehandlers, man lifts, and rigging equipment to maneuver large steel components into position and secure them to the existing building structure.
On-site welding was critical to achieving precise fit and alignment. While some components were pre-welded in our shop, much of the assembly required field welding to ensure proper load transfer and structural integrity. Each section was fastened using a combination of welds and mechanical fasteners.
Midway through the project, the installation schedule changed, requiring completion four weeks earlier than originally planned. To meet the accelerated timeline, we increased manpower, brought in trusted local subcontractors, and extended work hours, including weekends. These adjustments allowed us to stay on schedule without compromising quality or safety.
A Floating Staircase Built to Last
When the project was complete, Dick’s Sporting Goods had a mezzanine and staircase that combined structural performance with visual impact.
By partnering with Macy Industries, they received:
- A floating metal staircase that delivers an open, modern appearance
- Custom metal handrails designed for durability and full code compliance
- A fully self-supporting mezzanine that provides seamless access between floors
- A completed installation delivered on time despite a significantly shortened schedule
At our NH sheet metal fabrication shop, we do more than build components. We engineer solutions that perform in real-world environments. Whether you need a custom metal staircase, structural handrails, or another industrial sheet metal fabrication project, our team has the expertise to bring your vision to life.
When precision, durability, and efficiency matter, Macy Industries delivers. Do you have an upcoming project you would like to discuss? Let’s talk.