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Client: Tandem / Sanctuary
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Location: Northbrooks House, Harlow, Essex
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Sector: Residential Development
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Services: Architectural Metalwork, Balustrades, Balconies, Remedial Works
Project Overview
Blackburn & Co. Ltd was appointed to deliver a comprehensive architectural metalwork package at Northbrooks House after the main contractor inherited the project from a previous contractor. The works involved a combination of new installations and remedial solutions across multiple residential blocks and house plots, requiring careful assessment, redesign, and bespoke fabrication.
Scope of Works
Our scope included the survey, design, manufacture, and installation of:
- Balconies to Levels 1–3
- Stair core balustrades to Blocks A & B (three floors each)
- Ground floor wall railings (approximately 100 metres)
- Remedial works to existing house plot balconies
Balconies – Levels 2 & 3
The Level 2 and Level 3 balconies followed a similar design; however, installation presented significant structural challenges. The balcony decks consisted of unfixed patio-style slabs, meaning there was no suitable substrate beneath for fixings. As a result, all balcony balustrades had to be fixed into the brickwork at either side only.
At Level 3, further complications arose as the parapet brickwork was insufficient to withstand the required lateral loads. To overcome this, a larger top rail section was introduced, designed to act as a cantilever, with fixings positioned at either end into suitable brickwork. To control deflection, the bottom rail was supported using an RSA, ensuring compliance with structural performance requirements.
Due to their size and weight, these balconies were fabricated as single-piece units and installed using a crane, as they could not be transported through the building internally.
Stair Core Balustrades – Blocks A & B
Balustrades were installed across three floors in two separate stair cores, each presenting different spatial constraints:
- Block A: Due to width limitations, the balustrade was side fixed, allowing the minimum required distance between the balustrade and the wall-mounted handrail.
- Block B: Insufficient space between the concrete stairs prevented side fixing, so the balustrade was top fixed. Panels were pushed closer to the edge, with fixings offset to maintain minimum handrail clearances.
Each stair core required a bespoke fixing strategy while maintaining a consistent visual appearance across both blocks.
Ground Floor Wall Railings
The ground floor walls required railings along all top faces, totalling approximately 100 metres. Due to many of the walls being of single-skin construction, all railings were side fixed, ensuring a secure installation without compromising the integrity of the wall structure.
Remedial Works – House Plot Balconies
The development included several house plots where balcony railings had been left on site by the previous contractor. Following assessment, it was found that the brick parapets lacked sufficient reinforcement to support the original fixing method.
A revised solution was developed involving a larger top rail section, fixed back into the brickwork at either side to act as a cantilever. Angle brackets were introduced at the bottom rail to eliminate deflection and ensure structural stability.
Delivery & Outcome
All areas were fully surveyed, designed, manufactured, and installed by our in-house team. Manufacturing was completed within six weeks, followed by a five-week installation programme, delivered efficiently despite the project’s complexity and inherited challenges.
The finished installation provides safe, compliant, and visually consistent architectural metalwork throughout the development, resolving previous design issues and delivering a robust long-term solution for the client.
Get in Touch
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