Modular Balcony Construction with Galvanized Steel

The Residential Apartment Development at Station Road, Raheny has been named a finalist at the 2025 Irish Steel Awards in the Architectural Metalwork – Balconies category. Arc Engineering designed and delivered more than 100 bespoke balcony units for the project, while Galco hot dip galvanized over 53 tons of steel, ensuring durability and long-term protection.

Station Road, Raheny is more than just a residential scheme. This landmark project transformed a tight urban infill site into a modern development of 105 apartments spread across a single building of four to seven storeys.

The design maximises natural light and ventilation with balconies and terraces on all elevations, giving residents outdoor amenity space while enhancing the building’s architectural identity.

Arc Engineering was appointed by Earlsfort Homes to design, manufacture, and deliver a full balcony package. The scope included supported, cantilevered, double, and corner balconies, as well as concrete balustrade sets, saw tooth solar shading stacks, and canopies.

Every balcony was fully fabricated offsite, delivered as a prefinished modular unit, and protected with hot dip galvanizing for long-lasting performance.

Complex Challenges

One of the main design challenges came from the variation in façade depths created by the mix of materials – brick, render, and zinc. Each balcony required precise alignment and structural adaptation.

–The balcony package was particularly complex, incorporating a variety of balcony types –  explains Jason McLoughlin, Project Manager at Earlsfort Homes. – Seven of the saw tooth balconies were specifically designed to house bespoke solar shading fins on the north elevation, adding both architectural definition and significant engineering complexity to the façade strategy.

Beyond design complexity, the site itself created further obstacles. With limited storage and tight access, every delivery had to be planned with precision. A just-in-time logistics strategy ensured smooth crane lifts and avoided unnecessary delays.

Why Hot Dip Galvanizing?

For this project, Galco hot dip galvanized over 53 tons of steel, providing critical advantages:

• Long-term durability – 70+ years of maintenance-free protection, ideal for exposed environments.
• Accelerated construction – Steel arrived ready to install, eliminating painting, coating, or on-site preparation.
• Low maintenance – A robust coating reduces life-cycle costs by minimising upkeep.
• Ease of inspection – A uniform galvanized finish is simple to check visually, with quick non-destructive testing available.
• Proven performance – A trusted solution with decades of reliable results across marine, industrial, and residential applications.

Balconies Built to Last

The offsite modular construction approach was key to project success. Prefinished balcony units were lifted directly into place by crane, reducing site work, crane time, and overall disruption.

Hot dip galvanizing by Galco ensured the balconies were both ready-to-use and built to last, supporting the project’s tight timeline while guaranteeing long-term durability.

The result is a residential development that delivers on design, efficiency, and resilience – now recognised as a finalist at the Irish Steel Awards 2025.

Project Team

Client: Earlsfort Group

Construction Management: Earlsfort Homes

Main Contractor: M&P Construction

Architect: PMCA

Structural Engineer: CS Consulting Group

Quantity Surveyor: Thaddeus Jessup & Associates