Cut Flat-sided Oval Tube Features in Stunning Recessed Handrail Project

How Timeless client Metcalfe overcame fabrication challenges to achieve a unique handrail design

Achieving unique designs often requires embracing trial and error. Timeless had the pleasure of working with pioneering UK-based bespoke steel fabricators Metcalfe on a one-of-a-kind recessed handrail project, combining precise engineering with creative design.

Metcalfe approached us with a design challenge — a recessed handrail unlike any handrail Timeless have worked on before. Metcalfe’s commitment to pushing the boundaries of form and function enabled them to actualise their client’s vision, even after the initial prototype didn’t turn out as planned.

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Experimenting with tube size until the right form was achieved 

For the first attempt, we supplied Metcalfe with two lengths of stainless steel 304 flat-sided oval tube measuring 55 x 25 x 2mm. This was a custom-made size requested by Metcalfe, which we were able to make with existing tooling. However, their fabricators discovered that it didn’t hold the shape they wanted due to the innate springiness of stainless steel. This size of tube curled in more than expected during the cutting process, which meant going back to the drawing board to source a larger tube. 

Timeless then supplied a length of flat-sided oval tube in 86.5 x 27 x 2mm — which when cut provided an aperture wide enough for a hand to fit comfortably.

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LED lighting and brushed stainless steel: a winning combination

Metcalfe incorporated LED lighting into the handrail, adding an element of functional beauty within this robust stainless steel setting. When paired with integrated LED lighting, a recessed handrail creates a guiding path that enhances both visibility and ambiance — perfect for dimly lit corridors or as a subtle design feature in upscale environments. The brushed stainless steel finish of the tube added to the appealing modern aesthetic.

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The benefits of recessed handrail

Recessed handrails, like Metcalfe’s design, can bring ergonomic and aesthetic benefits to modern spaces. Recessed handrails provide a seamless look, as they integrate smoothly into walls or other surfaces, creating a clean, minimalist appearance. They can also help to maximise space and maintain unobstructed pathways in high-traffic areas.

In addition to aesthetics, recessed handrails also enhance safety and accessibility. Their flush installation reduces the risk of accidental bumps or snags. Their unobtrusive nature, combined with a robust material like stainless steel, ensures they can withstand substantial use.

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Using tube profiles to create innovative railings 

“It is always exciting to work with clients who are prepared to experiment with materials to create new and interesting designs. Projects like these remind us of the importance of adaptability. Metcalfe’s efforts resulted in a bespoke handrail design that is genuinely unique. And we now know that cutting flat-sided oval tube can provide an ideal profile for recessed handrail” says Timeless Tube’s Managing Director Tom McMillan.

“At Timeless Tube we take great pleasure seeing how our shaped metal tubes can support our clients’ distinctive and original work.” adds McMillan.

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