Inside the Fan Tent washrooms at the PNE Amphitheatre, four communal stainless-steel sinks wrap around structural columns. Each is three-sided, custom-fabricated, and built for heavy public use. Foundry designed, fabricated, and installed the project, subcontracted through Towne Millwork, with coordination across EllisDon and the site team.
While the overall project concept was clear, the transition from design to execution needed careful coordination.
From drawing to metal
Each sink had to wrap a structural column. The designer’s model used stone tops, and Foundry’s first task was to turn that concept into a stainless-steel solution that could be fabricated, shipped, and assembled around fixed site conditions.
“What made this package unique was translating the designer’s stone top model and drawings into real-life stainless steel,” says Jason Worsley, general manager of stainless fabrication. “There was an immense amount of collaboration with our top fabricators and installers to ensure we could move the sinks through the shop with the accuracy, finish, and efficiency that defines Foundry.”
The column locations, finish requirements, site access, and delivery constraints all had to be factored in before fabrication started.
“From a layout and design perspective, it was a welcome breath of fresh air,” says Jason. “A unique challenge compared to the run-of-the-mill stainless fixtures we produce day in and day out.”
Built in sections
Because the sinks had to fit around fixed columns, single-unit fabrication wasn’t possible. Foundry built them in sections, completing as much work as possible in the shop, then assembling on site.
A primary challenge was working around the fixed site columns. Site conditions, delivery logistics, and scheduling played significant roles in both the design process and execution. The team prioritized fabricating as much as possible in the shop to minimize on-site workload for installers.
Accurate site measurements and a clear sequencing plan were what made that approach work.
The install
Four custom communal wash sinks, designed around fixed site conditions, fabricated in sections, and installed in a high-volume public venue. The column constraint that shaped the design is invisible in the finished space.
Mitch Webb led the installation. The density of custom work in each unit made consistency the main challenge.
“Every piece was one of a kind, all curved and designed with specific reveals, which are intentional gaps or edges, plus concealed and removable components,” says Mitch. “Keeping things consistent, especially with stainless steel, was very difficult.”
The team used templates for each piece to maintain alignment. They also had to work around existing services and deal with a concrete slab that was out of level, which meant custom-cutting and scribing (precisely marking and trimming) flashing (thin metal covering at the fixture base) on-site to close gaps and keep the finished fixtures looking clean.
In a public washroom built for heavy use, the flashing is what separates a clean installation from one that shows its seams, and the concrete slab being out of level meant that every piece had to be custom-cut and scribed on site.
Coordination across the project team
Project Manager Tanika Thakur managed communication across Foundry, Towne Millwork, EllisDon, and the site team. With four unique sink islands, each custom-fabricated to its specific column location, design details, field measurements, and installation requirements, all parties had to keep these details up to date throughout the project.
Foundry’s installers were involved from early site measurements through to final installation. Because the units shipped in sections, labelling and sequencing were also part of keeping the assembly on track.
“The fabrication had to balance an elevated aesthetic design with extreme durability,” says Tanika. “Accurate field measurements, early coordination, and strong communication were critical to keeping the project on schedule.”
fouCurious about what Foundry can build for your next project? Contact our team to talk through custom stainless fabrication, commercial kitchen solutions, or site-specific project requirements.