Manufacturing, Transport & Installation
Manufacturing, Transport & Installation of Curved Concrete Staircases
Precision-Built Offsite. Delivered and Installed with Care.
We pride ourselves on delivering premium, bespoke precast concrete staircases, from initial concept through to final installation. This page outlines the key manufacturing constraints, transport logistics, and site installation requirements involved in the delivery of your curved or helical concrete stair flight.
Manufacturing Considerations
Each storey-height curved stair flight is manufactured upside down in our Essex-based facility, using adjustable palletised moulds. This flexible moulding system enables a wide range of bespoke shapes and profiles, offering exceptional design freedom for our clients.
However, the following manufacturing limitations apply:
- Plan Angle
- Maximum plan angle per flight: 270° (due to factory space constraints)
- Riser Range & Flight Width
- Riser range 150–225mm → Max flight width: 1800mm
- Soffit Finish
- Flights are cast upside down, resulting in a trowelled soffit finish
- Cast-in lifting anchors are included for handling and may also be used for securing units during transport
- A plaster skim finish may be required post-installation (by others)
- Treads, Risers & Strings
- These components will have a clean ex-mould finish
- Cast-in lifting anchors are required for rotation after demoulding and for lifting during transportation and installation
Transportation
As a division of Milbank Concrete Products, we have access to a plethora of delivery vehicles from within an industry-leading logistics network. Our specialist precast concrete stair units are carefully loaded at our factory headquarters in Essex and delivered directly to site in preparation for installation all over the United Kingdom.
In some cases, if the width of the stair unit on the delivery exceeds 2.9m, the load is categorised as “abnormal” and will be subject to certain restrictions. We are more than happy to assist with support vehicles/abnormal delivery requirements if necessary. The maximum height of a load is 4.5m, so in some instances it may be necessary to use a low loader rather than a standard flatbed vehicle.
Expert Installation Services
Kallisto provides a safe, efficient, and fully managed installation service for all precast concrete staircases. Our in-house fixing teams are highly experienced in positioning complex and architecturally intricate precast units, ensuring precision and care throughout the process. We work closely with mobile crane hire specialists Cadman Cranes to deliver reliable and professional lifting operations across projects of all sizes throughout the UK.
Access and Lifting Requirements
Precast stair flights are substantial in weight, typically ranging from 2 to 12 tonnes. As such, a mobile crane is required to offload and position the units directly into place. It is essential to understand that installation is only possible where roof access is available. Due to the size and mass of the units, they cannot be manoeuvred on the ground using trolleys or similar equipment. This means installations are not feasible in renovation developments where the roof structure remains intact.
Crane Planning and Site Logistics
The assumed crane size and operational footprint will be included within your project quotation. For instance, a 35-tonne mobile crane, when fully rigged, generally occupies an area of approximately 12 metres by 8 metres. Final crane specifications, lift radius, and access requirements will be confirmed following a site inspection and outlined in the job-specific lift plan and Safe Working Method Statement to ensure safe and efficient installation.
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Whether you’re an architect, developer, or private client, our team is here to bring your staircase design to life.