Perforated Corten Steel Flooring Panels for a Council Building
Think Perforation, Think Graepels. Precision Perforation for Perfect Results
Graepels engineered and manufactured bespoke perforated Corten steel flooring panels for a public walkway in Barnsley, combining a distinctive picture perforation design with strength, durability and material efficiency.
Why Choose Graepels?
We have almost 70 years of experience across the UK and Ireland, with expertise in perforated metal, woven wire, metal fabrication, laser cutting, and ISO 9001 certified manufacturing.
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The Project at a Glance
The Client
The Project
We Are Fully Accredited & Award-Winning
The Brief
What was the project?
The project involved the manufacture of bespoke perforated Corten steel flooring panels for a public pedestrian walkway in Barnsley. The flooring was designed to incorporate a unique picture perforation pattern while meeting the structural requirements of a public realm application.
What problem needed to be solved?
The original design specified 8mm thick Corten steel panels to achieve the required loading performance. This created cost and material efficiency challenges, prompting the project team to explore alternative solutions.
What were the key requirements?
- Achieve the required pedestrian loading performance.
- Maintain the architectural intent of the THE SEAM picture perforation design.
- Deliver a durable flooring solution suitable for public use.
- Reduce material usage and overall project costs where possible.
What challenges existed?
The main challenge was reducing the panel thickness without compromising structural performance. The perforated design also required careful consideration to ensure the flooring maintained adequate strength while achieving the desired visual effect.
The Solution
What did Graepels supply?
Graepels supplied 126 bespoke perforated Corten steel flooring panels covering approximately 76m² of walkway surface.
Was anything bespoke or innovative?
Yes. Graepels developed an alternative engineering solution using 4mm Corten steel combined with a concealed support bar and welded reinforcement ribs. This allowed the material thickness to be reduced from the originally specified 8mm while maintaining the required load-bearing performance.
What materials, finishes or manufacturing processes were used?
- 4mm Corten Grade A steel.
- Double brushed and vacuum cleaned finish.
- Picture perforation using THE SEAM design.
- Folded panels with 40mm folds and 25mm returns.
- Welded reinforcement ribs.
- Hidden 4mm support bar along the panel length for additional strength.
How were the challenges addressed?
The structural requirements were met by incorporating a hidden support bar and reinforcement into the panel design. Testing demonstrated that the flooring comfortably exceeded the specified loading criteria while allowing significant material savings compared with the original 8mm design.
The Outcome
What was achieved?
A structurally efficient and visually distinctive pedestrian walkway flooring system was successfully delivered for the project.
What benefits were delivered?
- Reduced material usage.
- Lower overall project costs.
- Maintained structural performance requirements.
- Delivered the desired architectural appearance.
How did the solution improve safety, durability, performance or maintenance?
The reinforced panel design provided the strength required for public pedestrian use while utilising durable Corten steel construction suitable for an external environment. The engineered solution achieved the necessary load performance without increasing weight or complexity.
Why was the project successful?
The project demonstrated Graepels’ ability to combine engineering expertise with specialist perforation manufacturing. By challenging the original specification and developing a more efficient alternative, Graepels delivered a solution that balanced aesthetics, performance and value while meeting the project’s technical requirements.