White Oak Balustrade

The view encapsulates the vibe - concrete, wood & metal.

Some jobs are traditional, some are pushing the envelope - this is somewhere in between. A good friend of ours built a barndominium, with some traditional materials, and modern designs. The ‘Barndo’ has an open concept, with extraordinarily high ceilings at 18’ to the highest point.

One of our jobs was to craft a balustrade (or guard rail), where the second story balcony has a 12’ drop to a finished concrete floor. Among many considerations, the 2 most important were:

1. Keep it straight across 25’.

2. Hide all the fasteners.

Bright orange string line drawn across our posts

For the first, we used an ancient, but not archaic method - the string line. Once we had the fixed the 2 end posts, a tight line was strung between them, which ensured a true and straight guard rail.

The subfloor also fluctuated in height, so we made use of a modern string - a laser level - to make sure the tops of our newel posts were consistent.

For the second consideration, we used friction, tension, concealment, dominos, and high-grade construction adhesive to ensure strength, durability, and no visible fasteners.

We used the Festool Domino DF 500, and Beachwood connections to join our material. This tool is portable, and makes incredibly strong joints, all without leaving the job site. The finish product meant wider planks of white oak than were supplied, or even available.

Studies have shown that wasted steps can cost $60 each in missed revenues. This is why our job sites often have workstations, up to 5 at any given time. Cutting, joining, sanding, assembly, and finishing all have their own place to increase efficiency.

Tim at a cut station with handrail material

Once all the posts, top plates, and handrails were in place, we carefully installed every iron baluster. The fitment had to be precise enough to hold secure, but loose enough to assemble.

After all carpentry was complete, the painters came through and applied clear coat to all of the white oak, giving a soft lustre to the beautiful grain.

Finished newel post displays wood grain, angles & shadow lines

We are grateful for the opportunity to shape beautiful, natural materials into something functional and aesthetically pleasing. Our work is now a focal point in our friend’s home, a structural beauty that invites them downstairs every morning for coffee.

This photo illustrates a cohesive interior design, one which pairs decor and finishes in a tasteful way