Nothing standard. Everything possible.

Close-up of an organic perforated bronze railing panel beside dark wood floating treads

Some ideas don’t come with a blueprint.

They come with a sketch, a question, or a shape that doesn’t exist yet. We’re a metal fabrication house at our core, working in a single facility where nothing leaves our hands until it’s finished. Special Projects is where capability meets no boundaries.

DISCUSS YOUR PROJECT

Glass and bronze-framed elevator shaft integrated beside a curved staircase with wood treads

Bird's-eye view of a curved staircase with wood treads, dark steel stringer, and glass railing

Our broad spectrum of capabilities means almost any project is possible. If you can imagine it, we can build it.

Design & Engineering

We turn a concept into something buildable, developing detailed drawings, specifications, and engineering calculations for every project. Mockups, samples, and material and finish testing let us validate choices before fabrication begins. Throughout this process, we collaborate closely with you to ensure the solution fits both the vision and the budget.

Cost estimates and budgeting
Design development and shop drawings
3D visualization modeling
Mockups and samples
Engineering calculations
Material and finish specifications
Fabrication and manufacturing planning
Lighting, wood, and glass integration
Motorization, automation, and mechanism design

Project Management

We manage each project from initialization to delivery, using digital field surveys, BIM coordination, field logistics development, and more to keep design and site conditions aligned. Budgets and schedules are tracked throughout, so nothing surfaces late in the process. One team oversees the work from start to finish.

Project management and oversight
Budget analysis and tracking
Digital field surveys and BIM coordination
Project schedule management
Field logistics development
Installation means and methods
Maintenance program development

Fabrication

We turn architectural drawings and models into finished metalwork entirely on our own floor. Through our 3D Modeling Fabrication Release processes, we virtually validate every part and assemblage before a single piece of material is cut.

This becomes the starting point for our fabrication teams involving skilled welding, metal forming/bending, material finishing, alongside an array of high precision CNC driven milling, cutting and drilling machines. From traditional blacksmithing techniques to state-of-the-art metal forming capabilities, we cover the entire architectural spectrum. Our range lets us take on forms and details that would otherwise require several outside shops to complete.

Welding and fabrication
CNC machining and bending
Metal finishing (patina, polishing, media blasting, plating, paint, powder coat)
Waterjet and laser cutting
Blacksmithing and forging
Modeling and casting (sand and investment)

Finishing

Material selection is only half the equation. Our in-house finishing artists carry every piece through to its final character, applying the technique each design calls for rather than a single standard process. Every living patina, graining pattern, and paint system is developed and tested in-house, so the finish is held to the same standard as the engineering underneath it.

Custom living patina finishes on steel, stainless steel, and bronze
Directional and orbital graining, texturing, and polishing
Custom wood treatments across a range of species
High-performance paints, including exterior and marine grade
Layered paint application for metallic finishes
Plating and multi-layer coating systems

Stay tuned for an exploratory preview of our in-house custom finishes.

Installation

Getting a finished piece from our shop to its final location is part of the job, not a separate one. We handle transport, rigging, and erection ourselves, on-site and off, so the same standards that shaped the piece carry through to how it’s installed.Additionally, our commitment to installation extends to safety, protection and cleanliness.

Project transport and handling
Onsite and offsite rigging
Erection and installation

Featured special projects

Special projects where the magic is nestled in the details.

Twisting, cantilevered stair with detailed ironwork within the guardrail

Historic

Custom curved, cantilevered stair with rolled, hand forged steel guardrails and wood handrails

Historic

A floor-to-ceiling steel lattice custom staircase

Contemporary

Rendering of a custom 30-foot, continuous spanning spiral staircase that wraps around a major building column

Contemporary

Custom nickel silver clad stair structure

Contemporary

Custom sweeping curved staircase with ornate scroll-pattern railing in a grand entry hall

Historic

Floating wood stair treads with custom bronze lattice railing panel

Contemporary

Custom bronze stair railing with square collar spindles and carved stone treads

Traditional

Custom floating staircase with wood treads and frameless glass railing

Contemporary

Custom floating staircase with wood and a glass railing, spanning multiple floors beneath a wood ceiling and glass walls

Contemporary

Custom curved floating staircase with glass railing and wood treads cantilevered from a metal stringer, set against floor-to-ceiling windows

Contemporary

Frequently asked questions

01 / SPECIAL PROJECT SCOPE

What qualifies as a Special Project?

An Iron Shop Special Project is any staircase, railing, or architectural metal piece built outside our standard product line, from a design that doesn’t exist in our catalog. It might start as a sketch, a set of engineering drawings, or a question about whether something is even possible. If the piece calls for custom engineering and fabrication rather than a standard configuration, you’re in the right place to start a conversation.

Do you only work with steel and aluminum?

Special Projects can bring unique materials to life far beyond steel and aluminum. Stainless steel and architectural bronze are common choices for their finished depth, developed through our “living” patina process. A single piece might also incorporate leather, cast or laminated glass, reclaimed timber and other wood species, stone or terrazzo, and synthetic materials. The same range applies to technique: a design might call on hand-forged blacksmithing methods, CNC-driven modern forming, or both within one piece.

Is there a minimum size or budget for a Special Project?

02 / DESIGN & ENGINEERING

What do I need to start a Special Project with Iron Shop?

Can I see a mock up or sample before fabrication begins?

Will a custom staircase or railing meet local building code?

03 / WORKING WITH YOUR PROJECT

Can you work directly with my architect or designer?

Yes, we can collaborate with architects and designers from an early concept. We can offer assistance in the development of architectural/design drawings as it relates to the piece, or support their effort in a reviewing capacity.

Generally, all Special Projects will come with detailed submittal drawings that help streamline the architectural/design process.

Can a contractor submit a Special Project on behalf of a client?

How long does a special project take?

Do you handle installation, or just fabrication?

Do you take on Special Projects outside of Pennsylvania?

Have additional questions?
Get in touch with us.

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