Process — Foundry Iron Works

DiscoveryWeek One

A phone call, then a site visit. We walk the property, take photographs, measure, and talk about what's there now and what's missing. We also talk about budget — frankly. Most of our work sits between $4,000 (a single bracket) and $90,000 (a full courtyard run). Anything outside that we'll tell you about over coffee.

DrawingWeeks Two – Three

We draw on paper, in pencil and ink, at full scale where it fits. Calvin handles most of the historical work; Marisol handles the modern. You'll receive scans by email and a hand-bound presentation copy by mail. Two rounds of revisions are built into the price. After approval, the proposal is fixed — no surprises at the end.

ForgeWeeks Three – Twelve

The longest stage. Stock arrives from our two suppliers in Salisbury and Greensboro. We cut, heat, hammer, weld, and fit each piece. The shop has three coal forges, two propane, a power hammer (a 1942 Bradley), and an English wheel for the curved plate. You're welcome to visit. Bring a coat — even in May the front of the shop is loud and cold near the bay door.

InstallFinal Week

Our crew of four loads the truck Sunday night, drives at 6am, and is on site by 7. Most rail installs take one to three days. Gates run two to five. We protect every surface, drill exactly where it's drawn, and clean up before we leave. Final walk-through happens with you at the end of the day. Touch-up paint goes in your basement for the future.

A few details.

The questions we get asked most often before signing a proposal. If yours isn't here, the phone gets answered Monday through Friday between 8am and 4pm by someone who works in the shop.

Materials

Mostly mild steel.

We work primarily in A36 hot-rolled mild steel because it forges well, welds cleanly, and ages with character. Stainless and aluminum on request. Brass and bronze for hardware and accents. Cast iron for period restoration only.

Finishes

Built to age.

Oiled black, beeswax-and-linseed, blackened patina, satin powder coat in any RAL color, or hand-painted with our restoration palette of fourteen historically accurate colors. We do not chrome-plate or galvanize unless code requires it.

Warranty

Twenty-five years.

Structural welds, mechanical joinery, and forged elements are warrantied for twenty-five years from install. Finishes are warrantied for ten. Surface rust on exterior pieces is not a defect — it's part of how the iron lives.

Service area

Mostly Charlotte.

We take on roughly thirty projects a year, most within Mecklenburg County. We travel to Asheville, Wilmington, and the Triangle for the right project. National work is rare but possible for restoration of historic landmarks.

The process.