Illinois State Capital

Contemporary Solutions for Antique Repairs

In partnership with the Office of the Architect of the Capitol, ChiLab Studio restored and updated the circa-1870 iron handrails on the 4th-floor gallery to meet modern ADA requirements while preserving their historic character. After removing layers of failing faux paint and documenting dozens of missing or broken ornamental pieces, we digitally modeled replacement components from archival profiles.

New upper ornamental details and toe-kick elements were developed as 3D models, then translated into match-plate sand patterns with carefully engineered gating systems. Masters were 3D-printed directly into the pattern boards, molded in resin-bonded sand, and used to cast multiple iron reproductions that seamlessly integrate with the originals.

For repairs to the original rail sections, lost-wax reproductions of the missing details were produced, assembled, and patinated to match the existing finish. Finally, a custom mill-worked wooden handrail cap was fitted atop the ironwork, providing both an elegant crown and the required clearance for ADA compliance. The result is a fully restored historic railing that honors its 19th-century craftsmanship while serving today’s needs.