Prefab Balcony Solutions with Sapphire

Overview

This article features Luke Haughton, President of Sapphire. Sapphire is a UK company specializing in prefab balcony technologies.

Company background

Sapphire started 32 years ago, in 1992.
The business began with balustrades and handrails for staircases.
Early products included stainless steel, glass, and hardwood handrails.
In 2012, a client project led to the creation of the patented Glide-On Balcony system.
Luke Haughton said the business was worth about $3 million when he joined and grew to over $60 million over the past 10 years.

Global presence and production

Sapphire operates across Europe, the USA, Canada, and New Zealand.
The company has nine factories worldwide.
It also uses storage facilities to hold products until they are needed on site.
Sapphire has a factory in Toronto for North American projects.
Since launching prefabricated balconies in 2012, the company has completed more than 40,000 units.

Design, quality, and installation

Sapphire starts with detailed design work to turn architect concepts into manufacturable products.
The company developed the Passport quality app, available on the Google Play Store.
Passport tracks production and installation.
The app provides traceability from material certificates to installer sign-offs.
Sapphire created a counterbalance lifter to install balconies under overhangs without chain clashes.
The company provides installer training through an on-site support team.
It uses a mix of 2D and 3D design depending on the market.
Its interface work supports different building types, including concrete and mass timber.

Technology and lean manufacturing

The Passport app includes factory controls, site controls, and a customer-facing portal. Customers can track project progress with real-time updates and photos.

Installation records and training

Installers first reached 22 balconies in one day.
The record later increased to 62 balconies in one day.
Teams receive trophies for record-setting work.
Sapphire works with a select number of teams in each market.
Installers receive certifications and regular refresher training.

Current work

The article says Sapphire has a new project in New York taking place this year.