Spiral Staircase For Trex Deck

Woodcrafter74

I'm doing a very large deck (1000+ sq/ft) for a customer in the Spring with Trex Brisillia (Cayenne). He's requesting a spiral staircase off one side of the deck, about a 10' drop. I obviously want it to match as best as possible. I found one company that will do an exterior spiral staircase with Trex treads (link attached). If I can get them to fab one with a handrail that's about 1 1/2" wide by 1/2" high, I could heat and bend one of the Trex handrails to fit over the steel, but then I'd still have to deal with the steel balusters and the customer wants all the balusters for the deck/stairs to be the standard square baluster.

I'm a little out of my league on this one. Anyone ever dealt with something similar?


http://www.spiral-staircases.com/all_steel.shtml

cdac

Set up your table saw with a dado blade to match the stair's balusters, groove all your trex balusters to a depth so that the notch is centered in the trex baluster, you will have a 3 sided baluster that you can slip over stair baluster. you can get trex facia then plane and rip it into strips that can be glued/inserted and sanded, get a long enough sona tube and reddy heater and create an oven to heat and bend your decorative hand rail. hope this helps.

Woodcrafter74

Chris, great suggestion on the three sided baluster. I had thought of ripping them in half, dadoing half the depth on each, then sandwiching them back onto the balusters. But I like your suggestion much better--only have cut lines on one side this way.

This whole gig is going to be labor intensive, but the homeowner is willing to pay.

Have you had any experience heating/bending the designer series trex railing? For the spiral it will have to bend horizontal and vertical. I think I'll be buying a few more clamps.