Projects
Wine cellar helicoidal staircase
Client
Industry
Services
Materials
Location
Turnaround
Confidential
Residential - Architectural
Laser cutting, custom fabrication, folding, MIG welding, powder coating
4mm mild steel G300 laser plate
Auckland, NZ
6 weeks
This project involved the fabrication of a custom two-piece helicoidal staircase providing access to an underground wine cellar. With a compact and challenging installation space, accuracy and precision were critical throughout the build.
As the project evolved, several design changes were introduced, requiring us to adapt on the fly. These included additional upturns, a custom spigot joining system between the two sections, modified tread shapes, and an alternative anchoring solution.
All treads were cut in-house on our laser cutter and formed using our press brake. Precise alignment of the treads was achieved using a riser jig, laser leveling, and meticulous measurement before MIG welding them to the central newel post.
This staircase highlights our ability to combine laser cutting, precision folding, and high-quality welding to deliver complex, custom solutions. At Metalshop, we take pride in tackling projects that require creative thinking and technical problem-solving.
Seismic Bracket Fabrication – Rucon Project
Our role and process
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Procurement: Bulk ordering of raw materials well ahead of time to avoid supply chain disruptions.
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Fabrication: Plasma and laser cutting of angle and plate, followed by custom welding for multiple bracket types.
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Manpower Allocation: Multiple welders were assigned to ensure production targets were consistently met.
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Quality Testing: Arranged prompt access to MPI testing to verify weld integrity and streamline sign-off prior to protective coating.
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Protective Coating: Coordinated closely with our sandblasting and painting partners, accounting for drying times and multiple coats to meet required durability standards.
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Logistics: Managed deliveries across the project timeline, including during the busy holiday period.
Client
Industry
Services
Materials
Location
Turnaround
Rucon
Construction
Custom jigs, laser cutting, plasma cutting, custom fabrication, mig & smaw welding, non destructive testing - magnetic particle inspection, sandblasting, priming, top coating
G300 Laser Plate 25mm, 12mm, 10mm, 6mm
Auckland, NZ
6 month roll out
We were engaged by Rucon to support a major seismic refit of a multi-storey commercial building undergoing a full redevelopment. A key part of this transformation involved seismic strengthening to ensure the structure met current compliance standards.
MetalShop worked closely with Rucon’s construction management team and structural engineers to manufacture over 1,500 custom seismic brackets. The complexity of the project meant that several types of brackets were required to suit different areas of the building—from the underground parking structure to upper-level office spaces. While most brackets followed two core designs, we also produced a number of specialised variations to accommodate tight spaces and obstructive columns.
Once the prototypes were approved, the design remained largely unchanged, enabling us to streamline production and reliably meet monthly delivery milestones.
Compliance and quality assurance were central to this project. Each bracket underwent Non-Destructive Testing (NDT)—specifically Magnetic Particle Inspection (MPI)—to ensure weld integrity and overall seismic performance. This rigorous testing process ensured the brackets were structurally sound and fit for their critical purpose.
Timing was crucial, as bracket installation was a key path dependency for other phases of construction. Our processes were carefully structured to maintain pace and deliver on time.