Market Sector:
ARCHITECTURAL STRUCTURES
MANUFACTURE OF BALCONIES
SAPPHIRE BALCONIES CASE STUDY
Manufacturing elegant, innovative balconies that are rigid, ready and right for apartments
Sapphire Balconies is a leading provider of factory-finished, modular balconies. It creates bespoke designs for developers of modern, high-specification apartments. The balconies use the firm’s patented Glide-On™ Cassette® system for fast, safe and simple installation. Sapphire’s Supply Chain Manager, Konrad Kaminski, explains what they look for in their manufacturing partners and why they chose Warren.
Innovation is at the heart of Sapphire’s story and stems from our belief that an hour in the factory saves ten onsite. Developers have traditionally used bolt-on steel balconies assembled onsite. That process is slow, error prone and costly, not least because installation requires scaffolding.
Konrad Kaminski, Sapphire’s Supply Chain Manager
Innovation is at the heart of Sapphire’s story and stems from our belief that an hour in the factory saves ten onsite. Developers have traditionally used bolt-on steel balconies assembled onsite. That process is slow, error prone and costly, not least because installation requires scaffolding.
Konrad Kaminski, Sapphire’s Supply Chain Manager
“Innovation is at the heart of Sapphire’s story and stems from our belief that an hour in the factory saves ten onsite,” says Konrad. “Developers have traditionally used bolt-on steel balconies assembled onsite. That process is slow, error prone and costly, not least because installation requires scaffolding.
“Sapphire realised there must be a better way that was fast, safe and efficient. They invested substantial time and resources in developing Sapphire’s patented Glide-On™ Cassette® system, which launched in 2012. We now have more than 50 patents and registered designs and our system is rapidly replacing the old, inefficient bolt-on process.”
Each Glide-On™ Cassette® (the frame, decking and balustrades) comes pre-assembled and factory finished to a high standard, so it requires minimal onsite finishing. Each one also has a unique identity and is individually quality checked, so the installers know exactly where each balcony goes. “By manufacturing and assembling the balconies offsite, including finishing in QUALICOAT powder coated colours, we ensure the integrity of each and every balcony,” explains Konrad.
RELIABLE SUPPLY CHAIN PARTNERS ARE ESSENTIAL FOR MAINTAINING QUALITY AND SERVICE
“Our attention to detail requires a really strong supply chain with partners we can trust. Just because we want to minimise time and costs doesn’t mean we want to cut corners – quite the opposite. What we save by working offsite, we invest in quality control to create the best balconies on the market.”
Sapphire, originally founded in 1992, has always held strong beliefs about how it does business. “We look to establish lasting, team relationships with customers, specifiers and suppliers,” says Konrad. “That is essential for us to protect our brand reputation for delivering balconies that are fit-for-purpose and conform to all legislation.
“We also look to harness the potential and talent of all our employees and we expect our subcontractors to treat theirs the same. That means providing all the necessary training and skills development. It also means creating a safe, satisfying and rewarding work environment and ethos.”
One of Sapphire’s main supply chain partners who has met those requirements since 2016 is Warren. “Sapphire initially chose them for their advanced manufacturing capabilities, to make and assemble our balconies,” says Konrad. “At first, they had to sub-contract the painting of our aluminium balconies but, as is the way with long supply chains, that caused understandable logistical issues.
“We must be able to assure our customers that we will build and finish all their balconies ready for installation when they need them. Thankfully Richard and Will at Warren understood our challenge and invested in the necessary on-site painting technology and training. Warren is now a fully accredited QUALICOAT architectural coater (one of only 24 in the UK and Ireland) that can deliver the quality of lacquering, painting and coating on aluminium and its alloys that Sapphire requires.”
SHARED VALUES AND A COMMITMENT TO PEOPLE MAKE FOR STRONG RELATIONSHIPS
As a result of that investment, Warren now hosts regular show-case events for Sapphire’s prestigious clients. Warren is also responsible for the storage of the finished items, ready for the developers to call for their delivery. It has a purpose built 1-hectare facility that, like its two main factories, is close to the A11 so providing fast access to London and the Midlands.
As Konrad says, “I always have time for Warren. They share our values, particularly around developing their employees’ potential. They also share our commitment to excellence, and in 2019 became our first supply chain partner to receive our coveted Gold Standard award for their work, which they have held ever since.
“It’s not just about their capabilities – which meet our needs – but also about the quality and skills of the people they have on their team. They are proactive and willing to invest to ensure they can deliver. That makes our relationship one of the strongest we have.”
As well as the all-important powder coating finish in specified colours to the QUALICOAT standard, Warren offers a full manufacturing service. This includes laser cutting, folding and forming, as well as machining. Warren also buys in essential materials, fully assembles each balcony and carries out stringent quality control checks.
DELIVERING ENGINEERED INNOVATION
Our customers love the results for three main reasons, first because our balconies look great, so adding to the value of the development. Second because we design and make them specifically for each development, so the architects can specify the exact finish they want. Third because they simply slide into place, so they are about 10-times faster to install than traditional bolt-on balconies (our record is 62 balconies installed in a day).
Konrad Kaminski, Sapphire’s Supply Chain Manager
Our customers love the results for three main reasons, first because our balconies look great, so adding to the value of the development. Second because we design and make them specifically for each development, so the architects can specify the exact finish they want. Third because they simply slide into place, so they are about 10-times faster to install than traditional bolt-on balconies (our record is 62 balconies installed in a day).
Konrad Kaminski, Sapphire’s Supply Chain Manager
Sapphire’s passion for innovation has led it to develop a range of other balcony related products, such as anchors that solve the common ‘bouncy balconies’ problem. They have also researched and improved deck finishes, soffits, drainage, cold bridging, and balustrade fixings. Warren has played its part in supporting these developments, including advising on Design for Manufacture.
“Our customers love the results for three main reasons,” says Konrad. “First because our balconies look great, so adding to the value of the development. Second because we design and make them specifically for each development, so the architects can specify the exact finish they want. Third because they simply slide into place, so they are about 10-times faster to install than traditional bolt-on balconies (our record is 62 balconies installed in a day).
“Warren’s excellent sustainability credentials are also becoming increasingly important to us. We are particularly interested in helping our architectural and developer clients reduce the whole life carbon emissions (WLC) of their buildings. That topic is rapidly rising up the construction industry agenda.”
Konrad concludes “I am happy to recommend Warren but I would rather keep them to myself. That said, Warren already works with our sister company MyDek and our shared R&D team at Innovast. And I encourage our supply chain partners to work together because ultimately that benefits Sapphire.”
Report by Huw Sayer at Business Writers Ltd for Warren.
