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Materials & Craftsmanship PDF Print E-mail

Chrome-Plated Steel Frames

The combination of traditional manufacturing and modern technology form the basic principle which makes it possible for our master craftsmen to make series production of the modern classics today.
The making of most of our articles begins with large piles of steel tubes of different sections and diameters being brought to the metal processing plant. Modern designers at that time chose 1 inch thick cold drawn steel tube, simply because it was widely available and rather inexpensive. There is nothing exceptional about this material; however, using it for high-quality furniture, it is converted into a main tool for making impressive craftwork.
Our frames are welded together in house using a specific pattern depending on the article
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In this picture, the Cubus Armchair LC 2
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The Cubus Armchair LC 2 and Cubus Two Seat Sofa LC 2 frames
The steel tubes used for Bauhaus Warehouse’ furniture are first cut to the appropriate lengths and curved by computer operated bending machines. This work can only be done by highly skilled professionals. Particular manual dexterity is required when working the delicate bends and curves with precision in order to achieve the narrow 90° angles of the original design. Subsequently the single pieces are welded together with precision.
Recently welded frames await their polishing before being sent out to the galvanization plant for chroming
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Detail of the 90 degree angle corners of our LC 2, LC 3 Recently welded frames for the LC 4 Chaiselounge
& Grand Confort Series inspired by Le Corbusier
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Detail of a polished frame carefully wrapped and ready to be sent to the galvanization plant for chroming
The beauty of chrome is evident in its mirror-like finish. It is a complex refinement process which transforms a raw grey piece of steel tube into a unique and contemporary designer product. Once the raw structure is completed, the seams of the welded sections are thoroughly and carefully hand-polished to a shiny surface which is done with the aid of wire brushes and grinding devices before receiving the 35 micron chrome-plating. One can only imagine the preciseness needed in this process, as any uneven patch would irrevocably spoil the final product.
All polished parts are then carried to the chrome-plating plant where the pieces are degreased in acid and rinsed in hot water in order to prepare the material for the galvanization baths. Note that any proper chroming process requires three steps where the material is dipped in different plating baths: Firstly, the steel receives a matte copper layer; secondly, a nickel layer; and lastly the 35 micron chrome plating itself.

The result is a long-lasting final craft product ready to be used for the making of a beautiful piece of furniture
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Detail of the Barcelona Series inspired by Mies van der Rohe

Aluminium-Cast Bases

The aluminum-cast Tulip bases are polished properly for lacquer process
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The bases on the left are unpolished while the ones on the right are polished and ready for lacquer
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Detail of Tulip bases for our Cocktail Table More detail of the various sizes of the Tulip bases for our Oval & Round Coffee Tables
Assembling of our Furniture
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Frames for our Barcelona Chairs are manually assembled The 32 cowhide straps are mounted onto the Barcelona frame
using 2 mirror-imaged pieces of suspension steel manually and tensed accordingly for support of the seat and
backrest cushions
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Finally, the frames are ready to be paired with respective cushions and are carefully wrapped to avoid chrome scratching

LC 2, LC 3 and Grand Confort Series Chaiselounge LC 4
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The frames for our LC 2, LC 3 & Grand Confort Series inspired The 35 nylon straps in various sizesare mounted onto the
by Le Corbusier are manually fitted with nylon straps hooked frame and tensed accordingly to provide the support
along all the sides of the frame for support of the seat cushions of the pad for our Chaiselounge LC 4 inspired by Le Corbusier
Leather
Being a natural product, leather is to be found in a wide range of individual and incomparably beautiful forms and appearance. The natural grain is just like our finger prints, so it will never be even nor the same from one piece of leather to another.
Bauhaus Warehouse' production
only accepts high-quality bovine leather of European origin to be used for our upholsteries
048_2 068_2 Our soft leather Our cowhide
Our leather is as natural as it can get. We do not press it to get rid of the natural grain which is its best feature yet. “Top grain” is the upper surface of a hide with its individual and natural grain. Only hides of animals that have not been injured or badly scarred are used to produce our leather. Our average thickness is approximately 0,8 to 1,1 mm. It assists in working the leather, but at the same time lets it keep the clean, stream-lined look well-known of the modern classic designs. Using thicker leather would not only make it difficult to work and achieve the desired shape, but would also give the final product an unnatural and ungainly look.
Before tanning the leather, the hides need to get trimmed and sorted out. Thanks to a meticulous quality control process, where the complete hide is machine-scanned for any defaults, any piece of lower quality is marked to be applied for invisible bottom parts of some furniture.
Our leather scanner looks for imperfections on the leather sheet.
The tanning is a very slow process. In order to preserve the beauty and softness of the leather, as well as to ensure high durability, we strictly abstain from using aggressive solvents. The leather is impregnated with the required shade of dye through a process called drum dying. This process ensures that the dye penetrates the full thickness of the leather; hence, retaining its colour for many years.
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The leather is manually cut to the sizes needed for the leather covers which are then individually sewn by our expert seamstresses.
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Seats of our Barcelona Chair in Ponyhide await mounting onto the prepared frames.
Beautiful pieces: Our Barcelona Chair and Ottoman in Ponyhide
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Examples of available Ponyhides

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Pony black-white Pony brown-white Pony black-brown-white
Upholstery
Compared to the manufacturing of 100 years ago, upholstery materials have widely changed. Now, we use dense, fire-retardant, shape-retaining and anti-allergic polyurethane foam for our products. On some of the furniture, such as the Grand Confort series, we use composite foam fillings with different grades of firmness to balance the weight placed on the front and back parts of the seat; and hence, render a perfect sitting comfort. Even after many years of use, our furniture will remain in its perfect shape.
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In this picture, the base cushion for the LC 2 Series inspired by Our foams with various densities covered with Dacron for maximum
Le Corbusier. A combination of 40-D (blue) and 30-D (white) confort and durability. This picture shows a lateral/back cushion
densities for maximum confort and durability for our LC 2 Series inspired by Le Corbusier
An air-tight vacuum is used to flatten the cushions for easy fitting of the leather covers
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For hygienical reasons, seat cushions and headrests are filled with Dacron foams today!
On special request we also may supply duck feather fillings

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Manufacturing of our Wooden Collection
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Left picture: Our skilled artisans make every effort to ensure out most quality
Right picture: Rolls of fabric and leather to upholster our chairs and lounge seatings
Wood
Bauhaus Warehouse uses slow-growing species of wood from controlled tree plantations of European origin. For a higher degree of stability and durability, it is important that the wood is stored and dried for years, prior to being used. This process prevents the wood from unintentional curving, cracking or chipping; and thus, guarantees beauty and consistency for the final product.
Some examples of the different wood types applied in our production
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Barrel Armchair inspired by Frank Lloyd Wright, Hardwood Bench, inspired by George Nelson, Coffee Table inspired by Isamu Noguchi, Hill House Chair inspired by Charles Rennie Mackintosh, Zig Zag Chair inspired by Gerrit Rietveld
Details of the production of our Stackable Chair 3107 and Armchair 3207 inspired by Arne Jacobsen
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The raw wooden seats await revision to ensure that The repaired and primed seats must be then hand polished
the wood has an even surface for priming and polishing prior to colour lacquer process consisting of 4 coats
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The lacquer machine handles sets of 4 chairs at the time. Everytime a new colour The colours for our lacquering are based
is used it is thoroughly cleaned to avoid mixing them on the international RAL charts.
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Seats await their last lacquer coat before the After sealing coat, the seats are taken into a closed and
translucid and sealing finish heated area to keep dust from settling on the fresh lacquer,
and for careful drying

More raw wooden structures for various articles of our Wooden Collection

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Packaging Material and Warehousing

Secure Faesite Crates, Pallets Made-to-Measure and Hard Cartons are used for Packaging

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Left picture: The marble tops for our Eero Saarinen collection are thoroughly crated to avoid cracks and damages.
Middle picture: Our glass tops (above for our Barcelona tables) are properly packed to prevend the glass from breaking.
Right picture: The packaging material used is a hard carton box which is thick enough for transport handling.

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Most frames are prepared in advance and set aside to be paired with the mattress or cushions in the colour desired for a more efficient and quick shipping time

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Frames for the Cubus Sofas LC 2 ready for shipment Mattresses and headrests for the Barcelona Daybed Saarinen Tulip bases