As always, the team at Macy Industries was up to the challenge. We worked closely with Dick’s engineers and architects to design, fabricate, and install a floating staircase and mezzanine that not only met strict OSHA and IBC-compliance standards but also provided the modern, open look they were looking for.
Engineering a Staircase That Defies Gravity
Most staircases are supported by vertical posts or attachments to the ceiling or floor. But for this project, the stairs and mezzanine had to stand entirely on their own without any vertical reinforcements.
Meeting that challenge required careful planning, precise engineering, and expert craftsmanship.
- The staircase and mezzanine had to handle high foot traffic without flexing or shifting.
- Custom metal handrails needed to be mounted directly to the floor joist and stair stringers, rather than anchored into concrete.
- Everything had to meet OSHA and IBC safety codes, from railing heights to stair rise and run dimensions.
Dick’s brought in an engineer to handle the building’s structural design. Then, once Macy came on board, we worked with a second engineer to continue modifying and improving the design to ensure the staircase and mezzanine were structurally sound, up to code, and built to last.
After six weeks of design refinements, which included adjusting calculations, tweaking materials, and ensuring the entire structure could support the weight of a fully occupied staircase (and then some), we were ready to move into fabrication.
Precision Fabrication for Strength and Durability
With the design finalized, our team got to work shaping raw steel into components for a fully functional mezzanine and stairway.
We used our 6-axis CNC plasma cutter to fabricate the custom metal handrails and railing assemblies. For the larger structural components—including the stair stringers and mezzanine framework—we used a bandsaw to cut the steel before prepping everything for installation.
The fabrication process involved:
- Cutting and prepping the stair stringers, mezzanine framework, and railings.
- Welding and polishing seams for a smooth, professional look.
- Painting components to achieve a polished finish.
- Packing and transporting all fabricated parts to the new store and staging them for installation.
With every piece delivered and ready to go, the real challenge was about to begin—installing a floating staircase with no direct floor supports inside a busy retail construction zone.
Bringing a Complex Design to Life
Installing a structure of this scale inside a commercial space is no small feat. With no vertical posts to anchor the structure, our team had to carefully maneuver the large steel components into place using telehandlers, man lifts, and rigging equipment. This equipment helped us position each piece so that we could secure it to the existing structure.
On-site welding played a major role in the installation process. Although we pre-welded some components in our sheet metal shop, much of the assembly required welding on location to ensure a precise fit. Due to the weight and complexity of the structure, our team worked methodically, fastening each section with a combination of welds and mechanical fasteners.
As the project progressed, the timeline shifted, and our team had to readjust our installation plans to accommodate a completion date that was 4 weeks sooner than we had anticipated! As always, the Macy team adapted to meet the challenge. Not only did we increase manpower by bringing in additional employees, but we also brought in trusted local subcontractors to assist with the installation. Our team worked extended hours and weekends to ensure the project stayed on track without compromising quality or safety.
A Floating Staircase Built to Last
By the time the project wrapped up, Dick’s Sporting Goods had a mezzanine and staircase that was both structurally sound and visually impressive.
By working with Macy Industries, they got:
- A floating metal staircase that provides an open, modern look
- Custom metal handrails designed for durability and compliance
- A fully self-supporting mezzanine that allows easy access between floors
- A completed project delivered on time despite a shortened schedule
At our NH sheet metal fabrication shop, we don’t just build components—we engineer solutions that work in the real world. 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’d like to discuss? Let’s talk.