Spiral Staircase with a Ton of Curves! 2026

Spiral Staircase with a Ton of Curves, this article shows how we built a spiral staircase using CAD, CNC and hand sculpting techniques.

Step 1: Design

A friend of mine was building a custom home and wanted a unique spiral staircase. I had determined the climb and stroke, and how each piece screwed together forming a propeller with a 10″ hole in the center. Each tread bolts to the previous one with long bolts and threaded inserts. Before starting the construction project, we took the CAD model and added curves to every surface that wasn't touched by feet. What we came up with was a very organic look and it became the sculptural element to unify the three floors.

Step 2: Efficient use of material

Once we had a finished model, we had to figure out how we were going to actually build it. Fortunately, he owned a machine shop with a CNC machine we could use.

We were then able to cut the reclaimed wood into the sizes we needed and join the blocks together to load it into the CNC machine.

Since the reclaimed wood had bolt holes and stains all over it, we either hid them or accentuated them to add to the character of the staircase.

Step 3: CNC Milling

Now that we had the blanks glued together, we could program the machine to cut them with robotic precision.

Using the final tread model combined with the wood blank model, we were able to use the CAM software to write toolpaths to remove excess material, leaving only our curved treads.

Step 4: Hand sanding

After the stair treads came out of the machine, they were still a little rough. Sanding should be done inside. We installed a small guide and put up some plastic walls. Sanding and grinding is a complicated job and the dust got everywhere in the house.

Each tread came out of the machine like a topographic map. All the curves were actually made of different layers with a lot of "steps" that needed to be smoothed out.

Using black spray paint, we were able to see exactly how much we had sanded so we could sand everything evenly.

Very aggressive sanding discs were used to get the black lines to where they were about to disappear.

Then it was sanded to make the lines almost disappear, followed by fine sanding until the black paint was gone.

Step 5: Glue

After sanding all the treads, thelined up and organized by color and grain pattern. Then it was time for a fitting and dry assembly. Each tread was driven into the concrete with a stainless steel rod.

The rod was epoxy coated into the stair tread, then epoxy coated into the concrete, just as an epoxy was applied to the tread before tightening the bolts.

It was a pretty complicated glue, but once we got it the process flowed smoothly. One problem we had was that the concrete epoxy went out too quickly in the mixing nozzle.

Step 6: Final Touches

After the steps and landings were in place, it was time to have some more fun. We weren't sure how we wanted the transitions to be and modeling something on the computer seemed counterproductive.

For the transitions, we leave a lot of wood to later be sculpted by hand.

CAD and CNC are great for many things, but certain things are better if done tactfully.

We decided that the simplest curve would be the most elegant. One transition was done in a matter of hours one day, the second the next day, then both were touched up at the end of the second day.

It would have taken longer to model what I did on the computer than it did to do it in the physical world. Also, when I tried to find something in CAD, there were too many options. When the raw form was presented in real life, it was clear what had to happen.

When everything was sanded and felt great to the touch, it was time to hang plastic on the walls and grease the stairs. We used a product called Waterlox which worked very well.

If you've ever oiled a nice piece of wood, you know how satisfying it is to completely transform a wood project. Bring out all the grain, deepen all the colors and let the true character of the wood shine.

In the end, this project was a great success. The rest of the house is unique and elegant. There's a strong industrial feel with lots of exposed concrete and steel, and this curvy wooden spiral staircase stands out as a great contrast.

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