Pure Copper Curved Railing,
This project is extremely interesting. It's created for a customer that had an existing railing of this design already in place. Seeing how much they loved it, they asked us to best emulate the existing railing.
Now, copper is rather difficult to weld with a tig machine because a) it requires massive amounts of amperage to weld, and b) copper is an excellent conductor of heat and electricity. So, to get the job done we used a Miller Syncrowave @ 300 amps with helium because it was really the only way to get the job done.
For the legs, we used 3/4x2 solid copper bars. We used this because it provides a heavy weight feel and clean, crisp corners. The material is ETP Copper C11000 H02.
To allow our helix to form fluidly, we carved 3d saddles into the solid copper with saw / grinder.
The top tube, since it was being welded to such a thick piece of copper, needed a thicker material so that it wouldn't just get blown through by the 300 amps of electrical force. We used Copper C10100 H80 (hard-drawn) / Made in Japan Oxygen free copper. Typically, this kind of copper would be used as an antenna or similar propose because the surface area inside of the tube would enhance the ability to send and receive signals.
The copper tube itself is a round 2x0.125 wall.
To form the railing we inserted the 3/8 round copper ETP Copper C11000 H02 rods though the posts. These required angles to be drilled on 2 angles at once for our helix to work.
We had custom copper caps spun from .100 copper to cover the ends of the railings with a smooth and rounded piece.
We then created a template on-site made from existing steel design and removed / copied that template railing in our shop, polishing it to perfection.
And, in case you missed it, the railing naturally patina's. This is a feature that the customer wanted because it's located near the ocean.
To ensure this railing stays where it should, we drilled though the blue stone stairs with a core drill and cast it in the legs with expanding anchoring grout.