Integrated wall panel and modular stair device, system, and method

Abstract

An enclosed modular stair system comprises a plurality of modular stair units. Each of the plurality of modular stair units are associated with a single story of a construction. Each modular stair unit comprises an upper rectangular landing, a mid-level rectangular landing, and stair runner that removably connect to the mid-level landing. Each of the plurality of modular stair units are organized such that a bottom modular stair unit is placed on a foundation and each successive modular stair unit of the plurality of modular stair units are stacked on top of and connected to a lower modular stair unit. The modular stair units also comprise a plurality of walls that connect to the base of the stair unit and are supported by the stair units.

Description

[0001] INTEGRATED WALL PANEL AND MODULAR STAIR

[0002] DEVICE, SYSTEM, AND METHOD

[0003] CROSS-REFERENCE TO RELATED APPLICATIONS

[0004] This application claims priority to and the benefit of U.S. Provisional Application No. 63 / 580,185, filed September 1, 2023, the contents of which is incorporated by reference herein in its entirety.

[0005] DESCRIPTION

[0006] FIELD

[0007] This application relates to a system and method for building stairs, and more particularly, to a system and method for building a modular stair system.

[0008] BACKGROUND

[0009] In both residential and commercial construction, the building of stairs enabling access from one level to another while conforming to local and national fire-proof ratings is a time-consuming process. Normally, the levels of a building structure are constructed and at some later point in time the stairs between levels are built as part of the previously built structure. In normal circumstances, this can take several days in order to build the stairs from the ground floor to the upper floors in a multilevel structure. After the stairs are built, it can take more days or weeks to provide sufficient structure to fire-proof the stairs. Additionally, when stairs from one level to another level have not been completed, alternative methods for moving between the levels, such as ladders, must be used to enable workers and inspectors to move between the different levels. The use of ladders and other temporary means for moving between levels are less safe than a normal stair structure. Additionally, temporary means for moving between levels requires additional set up and removal and are traditionally only present during the construction phase of a building. Thus, there is a need for the ability to more quickly construct stair structures within a residential or commercial construction that improves safety at the construction work site and minimizes construction time to improved efficiencies.

[0010] SUMMARY

[0011] The purpose and advantages of the disclosed subject matter will be set forth in and are apparent from the description that follows, as well as will be learned by practice of the disclosed subject matter. Additional advantages of the disclosed subject matter will be realized and attained by the devices particularly pointed out in the written description and claims hereof, as well as from the appended drawings.

[0012] To achieve these and other advantages and in accordance with the purpose of the disclosed subject matter, as embodied and broadly described, the disclosed subject matter includes a modular, enclosed, and self-supporting stair system that does not depend upon an additional structure for installation or erection. The self-supporting nature of the stair system and the composition of a single stair unit allows for a fully accessible walking path from level to level to be installed quickly and efficiently at a desired location, which may remain for the entire life cycle of the building. Additionally, by installing self-supporting stairs during construction, additional egress paths can be designed to eliminate the need for scaffolding systems to provide alternative access route for construction activities.

[0013] In accordance with an aspect of the disclosed subject matter, an enclosed modular stair system comprises a self-supporting modular stair unit that is configured to be self- supporting. The stair unit includes an upper landing having an upper landing area, a pair of first members, and a pair of second members, wherein an end of each respective first member is coupled with an end of each respective second member by a respective upper corner bracket, wherein the pair of first members and the pair of second members define a connecting band. The stair further includes a mid-level landing having a mid-level landing area, a pair of third members, and a pair of fourth members, wherein an end of each respective third member is coupled with an end of each respective fourth member by a respective mid comer bracket, wherein the mid-level landing area is smaller than the upper landing area. The stair further includes a plurality of comer support columns coupled with the upper and mid comer brackets to support the upper landing and the mid-level landing, wherein the upper landing is disposed at a top of the plurality of comer support columns and the mid-level landing is disposed at a mid-portion thereof, the plurality of corner support columns removably coupled to the upper landing and the mid-level landing. The stair unit further includes a first stair runner removably coupled to the mid-level landing and a second stair runner removably coupled to the mid-level landing and the upper landing. The stair unit further includes at least one wall coupled to the connecting band, wherein the plurality of corner support columns support the at least one wall and is configured to bear any load of the at least one wall, wherein the enclosed modular stair system is configured to be coupled with a second enclosed modular stair system by connecting a base of each of a plurality of corner support columns associated with the second enclosed modular stair system with the plurality of corner brackets of the enclosed modular stair system.

[0014] In accordance with an aspect of the disclosed subject matter, an enclosed modular stair system comprises a plurality of self-supporting modular stair units that are configured to be self-supporting, each of the plurality of self-supporting modular stair units associated with a particular level of a surrounding structure. Each of the plurality of self-supporting modular stair units further includes: an upper, rectangular landing comprised of a pair of first members connected at each end to a pair of second members defining a first rectangular area, wherein the pair of first members and the pair of second members each define a connecting band; a first plurality of corner brackets for connecting an end of a first member to an end of a second member; a mid-level, rectangular landing comprised of a pair of third members and a pair of fourth members interconnected at their ends defining a second rectangular area smaller than the first rectangular area; a second plurality of corner brackets for interconnecting an end of a third member with an end of a fourth member of the pair of fourth members; a plurality of comer support columns for supporting the upper, rectangular landing at a top portion thereof and the mid-level, rectangular landing at a mid-portion thereof without any support being provided by the surrounding structure, the plurality of comer support columns removably connected to the upper, rectangular landing and the mid-level, rectangular landing at the first and second plurality of comer brackets; a first stair runner removably connected to the mid-level, rectangular landing for connecting a bottom level to the mid-level, rectangular landing; a second stair runner removably connected to the mid-level, rectangular landing and the upper, rectangular landing for connecting the mid-level, rectangular landing to the upper landing; and at least one wall coupled to at least one connecting band of at least one of member of the pair of first members or the pair of second members, wherein the plurality of corner support columns support the plurality of walls and bear any load of the walls. Each of the plurality of self-supporting modular stair units are organized such that a bottom self-supporting modular stair unit is placed on a foundation and each successive self-supporting modular stair unit of the plurality of self-supporting modular stair units are stacked on top of and connected to a lower self-supporting modular stair unit by connecting a base of each of the plurality of comer support columns associated with an upper modular stair unit to a top of each of the plurality of corner support columns associated with a lower modular stair unit. In accordance with an aspect of the disclosed subject matter, a method for building an enclosed modular stair system comprising providing a first and second self- supporting enclosed modular stair unit that is configured to be self-supporting, wherein each of the first and second stair units includes an upper landing having an upper landing area, a pair of first members, and a pair of second members, wherein an end of each respective first member is coupled with an end of each respective second member by a respective upper comer bracket, wherein the pair of first members and the pair of second members define a connecting band, a mid-level landing having a mid-level landing area, a pair of third members, and a pair of fourth members, wherein an end of each respective third member is coupled with an end of each respective fourth member by a respective mid corner bracket, wherein the mid-level landing area is smaller than the upper landing area, a plurality of comer support columns coupled with the upper and mid comer brackets to support the upper landing and the mid-level landing, wherein the upper landing is disposed at a top of the plurality of comer support columns and the mid-level landing is disposed at a mid-portion thereof, the plurality of comer support columns removably coupled to the upper landing and the mid-level landing, a first stair runner removably coupled to the midlevel landing, a second stair runner removably coupled to the mid-level landing and the upper landing, and at least one wall coupled to the connecting band, wherein the plurality of corner support columns support the at least one wall and is configured to bear any load of the at least one wall. The method further comprising coupling the first stair unit with the second stair unit by connecting a base of each of a plurality of corner support columns associated with the second stair unit with the plurality of comer brackets of the first stair unit.

[0015] In accordance with an aspect of the disclosed subject matter, a method of building an enclosed modular stair system comprising: assembling an upper landing having an upper landing area, a pair of first members, and a pair of second members, wherein the assembling includes coupling an end of each respective first member with an end of each respective second member by a respective upper comer bracket, wherein the pair of first members and the pair of second members define a connecting band; assembling a midlevel landing having a mid-level landing area, a pair of third members, and a pair of fourth members, wherein the assembling includes coupling an end of each respective third member with an end of each respective fourth member by a respective mid comer bracket, wherein the mid-level landing area is smaller than the upper landing area; coupling a plurality of comer support columns with the upper and mid comer brackets to support the upper landing and the mid-level landing, wherein the upper landing is disposed at a top of the plurality of corner support columns and the mid-level landing is disposed at a midportion thereof, the plurality of corner support columns removably coupled to the upper landing and the mid-level landing; coupling a first stair runner to the mid-level landing; coupling a second stair runner to the mid-level landing and the upper landing, and coupling at least one wall to the connecting band, wherein the plurality of corner support columns support the at least one wall and is configured to bear any load of the at least one wall, wherein the enclosed modular stair system is configured to be coupled with a second enclosed modular stair system by connecting a base of each of a plurality of corner support columns associated with the second enclosed modular stair system with the plurality of corner brackets of the enclosed modular stair system.

[0016] In accordance with an aspect of the disclosed subject matter, a method for building an enclosed modular stair system comprising assembling a plurality of self-supporting modular stair units, each of the plurality of self-supporting modular stair units associated with a single story of a structure, each of the plurality of self-supporting modular stair units further comprising a self-supporting structure supported by a plurality of comer support columns, each of the plurality of self-supporting modular stair units comprising at least one wall; locating a first self-supporting modular stair unit on a foundation of the structure; securing the first self-supporting modular stair unit to the foundation of the structure; connecting at least one wall of the first self-supporting modular stair unit to a connecting band located on a top perimeter of the first self-supporting modular stair unit; connecting at least one wall of the second self-supporting modular stair unit to a connecting band located on a top perimeter of the second self-supporting modular stair unit; stacking a second self-supporting modular stair unit on top of the first self-supporting modular stair unit, wherein a top of a first plurality of corner support columns of the first self-supporting modular stair unit engage a base of a second plurality of corner support columns of the second self-supporting modular stair unit; and connecting a bottom of at least one wall of the second self-supporting modular stair unit to a top surface of the at least one wall of the first self-supporting modular stair unit.

[0017] It is to be understood that both the foregoing general description and the following detailed description and drawings are examples and are provided for purpose of illustration and not intended to limit the scope of the disclosed subject matter in any manner.

[0018] The accompanying drawings, which are incorporated in and constitute part of this specification, are included to illustrate and provide a further understanding of the devices of the disclosed subject matter. Together with the description, the drawings serve to explain the principles of the disclosed subject matter.

[0019] BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The subject matter of the application will be more readily understood from the following detailed description when read in conjunction with the accompanying drawings, in which: FIG. 1 illustrates a perspective view of the modular stair unit;

[0021] FIG. 2 illustrates a side view of the modular stair unit;

[0022] FIG. 3 illustrates an end view of the modular stair unit;

[0023] FIG. 4 illustrates an assembled stairwell structure using modular stair units;

[0024] FIG. 5 illustrates a flow diagram describing the process for building a modular stair unit;

[0025] FIG. 6 illustrates a flow diagram describing the process for assembling a stairwell;

[0026] FIG. 7 illustrates a configurable corner bracket;

[0027] FIG. 8 illustrates a comer support column;

[0028] FIG. 9 illustrates a foundation connection plate;

[0029] FIG. 10 illustrates a first side view of a connection sleeve and corner column;

[0030] FIG. 11 illustrates a second side view of a connection sleeve and comer column;

[0031] FIG. 12 illustrates a connection sleeve interconnecting first and second comer columns;

[0032] FIG. 13 illustrates a cross-sectional view of a stair runner;

[0033] FIG. 14 illustrates connection brackets for a stair runner;

[0034] FIG. 15 illustrates a top view of an upper level landing;

[0035] FIG. 16 illustrates the connection of the modular stair unit to a structure using Nelson studs; and

[0036] FIG. 17 illustrates a flow diagram describing the process for removing support columns from the self-supporting modular stair unit.

[0037] FIG. 18 illustrates a perspective view of the enclosed modular stair unit;

[0038] FIG. 19 illustrates a perspective view of an assembled stairwell structure using two enclosed modular stair units; FIG. 20 illustrates the process for assembling a structure using the enclosed modular stair units;

[0039] FIG. 21 illustrates a perspective view of an assembled stairwell structure using two enclosed modular stair units;

[0040] FIG. 22 illustrates a perspective view of the connecting surfaces of two walls;

[0041] FIG. 23 A and Fig. 23B illustrate the process for connecting two walls in the enclosed modular stair unit structure;

[0042] FIG. 24A and FIG. 24B illustrate side views of the wall connection assembly for enclosed modular stair units according to embodiments described herein.

[0043] DETAILED DESCRIPTION

[0044] Reference will now be made in detail to embodiments of the disclosed subject matter, an example of which is illustrated in the accompanying drawings. The disclosed subject matter will be described in conjunction with the detailed description of the system and methods.

[0045] Referring now to the drawings, wherein like reference numbers are used herein to designate like elements throughout, the various views and embodiments of a modular stair system are illustrated and described, and other possible embodiments are described. The figures are not necessarily drawn to scale, and in some instances the drawings have been exaggerated and / or simplified in places for illustrative purposes only. One of ordinary skill in the art will appreciate the many possible applications and variations based on the following examples of possible embodiments.

[0046] A modular stair unit 102 is illustrated in FIGS. 1-3. FIG. 1 illustrates a perspective view of the modular stair unit 102. FIG. 2 illustrates a side view of the modular stair unit, and FIG. 3 illustrates an end view of the modular stair unit. The modular stair unit 102 includes a top landing 104 and mid-landing 106. The top landing 104 is raised into the air using a group of four corner columns 108 and two central columns 110.

[0047] The comer columns 108 are removably connected to each corner of the top landing 104 using bolts or some other type of removable connecting means. The comer columns 108 in one embodiment comprise square tubular steel components of variable size. The size of the comer columns 108 can be adjusted based upon the number of stair modules 102 that are to be stacked upon one another. Larger rectangular sized columns 108 would be utilized for stacking more modules 102 on top of one another. The center columns 110 are mounted at some location along the long edge of the top landing 104 and are removably connected to the top landing 104 using bolts or some other type of removable connection.

[0048] The top landing 104 consist of a number of members connected in a rectangular shape having a pair of long sides 112 and a pair of short sides 114. Long members 112 and short members 114 are bolted together at their ends as will be more fully described herein below, to provide for the connection of different sizes of corner columns 108. In one embodiment, the long members 112 and the short members 114 comprise 12 inch beams.

[0049] The mid-landing 106 is adjustably connected to a point on a pair of the corner columns 108 and a pair of the center columns 110. Using bolts or some other type of removable connecting mechanism the mid-landing 106 can be moved to a plurality of locations between the top end of the pair of corner columns 108 and the pair of center columns 110 and the bottom of these columns. The mid-landing 106 also comprises a pair of long members 116 and a pair of short members 118 that are interconnected at their ends to form a rectangle that bolts to the comer columns 108 and center columns 110 as will be more fully described herein below. The long members 116 and short members 118 comprise in one embodiment 12 inch beams. A lower stair runner 120 provides steps from the ground level or floor level to the mid-landing 106. The upper stair runner 122 provides steps from the mid-landing 106 to the top landing 104. The lower stair runner 120 is removably connected to the midlanding 106 using bolts or some other type of removably connectable mechanism. The upper stair runner 122 is removably connected to the mid-landing 106 and the top landing 104 using bolts or some other type of removably connectable mechanism. Each of the lower stair runner 120 and the upper stair runner 122 consist of a pair of stringers 202 located on each side of the runners with a plurality of tread pans 124 located there between. The tread pans 124 consist of a metal well that can be filled with concrete in order to provide a step tread. The tread pans 124 can be used as stairs before the concrete is poured therein further speeding use of the stair modules 102 when assembled.

[0050] A number of railings 126 surround the outer edges of the upper landing 104 midlanding 106 and each of the upper stair runner 122 and lower stair runner 120. The railings are removably connected via bolts or some other type of removable connection mechanism and provide for safety of individuals using the modular stair system 102.

[0051] Referring now to FIG. 4, there is illustrated an assembled stairwell structure 402 utilizing four different modular stair units 102. The bottom modular stair unit 102A is secured to the foundation using a number of foundation brackets 404. The foundation brackets 404 are secured to the foundation using some type of foundation bolts, foundation screws or other type of foundation securing mechanism. Once the bottom modular stair unit 102A has been secured to the foundation, a next modular stair unit 102B is lowered into place on top of the bottom modular stair unit 102A. The modular stair unit 102B and the modular stair unit 102A are interconnected at their comer columns 108. The bottom of the corner columns 108 of the upper modular stair unit 102B are connected to the top of the corner columns of the bottom modular stair unit 102A using a connection sleeve 1002 (FIG. 10), as will be more fully described hereinbelow. The connection sleeve 1002 slides within the rectangular tubular member comprising the corner columns 108 and are then bolted thereto allowing the modular stair units 102A and 102B to be securely fastened to each other at each of the comer columns.

[0052] Modular stair unit 102C connects to modular stair unit 102B in a similar fashion. The base of the comer columns 108 of modular stair unit 102C are connected to the top of the comer columns 108 of modular stair unit 102B using the connection sleeve 1002. Likewise the top modular stair unit 102D has the base of its comer columns 108 connect to the top of the comer columns 108 of modular stair unit 102C. Each of the modular stair units 102 are lowered into place on the foundation or on to the previously placed modular stair unit using a crane. Referring now to FIG. 5, there is illustrated a flow diagram describing the process for assembling stairwell using the above described modular stair units 102. Initially, the individual modular stair units 102 are constructed at a remote location. The number of modular stair units 102 necessary for a particular construction site are constructed based upon the number of stairwells needed at a construction site and the number of levels within the structure being built. Once the required number of modular stair units 120 have been constructed, the modular stair units are disassembled at step 504 into their component parts. As discussed previously, the component parts comprise the top landing 104, mid-landing 106, upper stair runner 120, lower stair runner 122, corner columns 108, center columns 110 and railings 126. Each of these individual components are separated from each other by disconnecting the associated nut and bolt connections or other type of removable connection assembly utilized.

[0053] Next, each of the individual component parts are loaded onto trailers and transported at step 506 to the construction site. Once the disassembled modular stair units 102 arrive at the construction site, the modular stair units are reassembled at step 508 utilizing the same previously discussed nut and bolt type or other connection assembly utilized in the construction. Once the modular stair units 102 have been reassembled, the modular stair units can be stacked to construct a stairwell in a manner that will now be more fully discussed with respect to FIG. 6. Within the stacking process, the bottom modular stair unit 102 is first anchored at step 602 to the foundation of the structure. Next, the second modular stair unit 102 for the second floor is lowered on to the previously placed modular stair unit. The bottom of the corner columns 108 of the second modular stair unit 102 are aligned with the top of the corner columns of the lower modular stair unit and the second modular stair unit is leveled at step 606. The leveling mechanism will be more fully described hereinbelow. Once the second modular stair unit 102 is leveled, the second modular stair unit is connected at step 608 to the lower modular stair unit using the connection sleeves 1002. This process can then be repeated for each additional level by stacking the upper modular stair unit 102 onto the lower modular stair unit and connecting the corner columns 108 in a similar fashion. Once each of the modular stair units 102 have been placed and connected, the concrete stair treads can be poured at step 610 for each of the treads within the stairwell and the associated tread pans.

[0054] In this manner, a multi-level stairwell can be quickly built in just a few hours. Normally, the construction of a set of stairs within a multi-level structure will take several days in order to completely build the stair structure. By using the described modular stair units, the process can be completed in hours rather than days. The process additionally provides a number of safety factors to the construction site. Normally, a floor level must be created before the associated stair structure can be built as the stair structure is connected to and supported by the surrounding floor level. The modular stair unit system is self-supporting and can be erected even before any of the surrounding construction has been started. The associated floor level can then be built around the already established stairwell. The ability to erect the stair structure prior to or substantially concurrent with the building of the associated floor levels provides a high safety factor in that workers and inspectors are provided with a quicker ability to move between floors rather than using temporary ladders or other hazardous configurations.

[0055] A number of particular components enable the modular stair units 102 to be assembled as discussed in FIG. 5 and combined with other modular stair units as discussed in FIG. 6 in order to provide a multilevel stair structure. Referring now to FIG. 7, there is illustrated the adjustable manner in which the long sides 112 and short sides 114 of the top landing 104 can be connected with each other at their ends in order to provide a configurable connection for the use of different sized comer columns 108. The long sides 112 and short sides 114 of the top landing 104 are interconnected via an L- shaped corner bracket 702. The comer bracket 702 comprises a first member 704 and a second member that are interconnected along an edge 708 at an orthogonal angle.

[0056] The comer bracket 702 also defines holes 710 within the members 704 and 706 to enable the comer bracket to be bolted to a comer column 108. The holes 710 aligned with corresponding holes on the comer columns 108 in order to enable the corner columns and corner brackets to be bolted to each other. The corner bracket 702 is connected to the long member 112 and short member 114 via welding, bolting or other connection means. Since the long members 112 and short members 114 of the top landing 104 are interconnected with the comer bracket 702, the comer bracket 202 can be configured in different embodiments to bolt the two landings to different sized comer columns 108. Thus, the comer bracket 702 can have different sizes in order to accommodate different sized corner columns 108. A top landing 104 can be configured for different sized comer columns 108 by merely utilizing the appropriate comer bracket 702. Differing size comer columns 108 and corner brackets 702 would be utilized depending upon the number of modular stair units 102 that were to be stacked for a particular stairwell. A greater number of stacked modular stair units 102 require the use of larger corner columns 108 as the structure is self-supporting and larger beams are needed to support the greater weight of more modular stair units within a stack.

[0057] Referring now also to FIG. 8, there is illustrated a corner column 108. As mentioned above, the corner columns can be different sizes depending on the number of levels to be supported in the stair well. The corner column 108 includes holes 802 located at a top end thereof. The holes 802 located at the top end of the corner column 108 enable the modular stair unit 102 stacked on top of the corner columns 108 to be leveled through a connection sleeve as will be more fully described herein below. Multiple holes 802 allow corners of the modular stair unit 102 above the column 108 to be placed at various levels. The comer columns 108 are constructed of a rectangular tubular steel and can be of different sizes depending upon the number of levels to be stacked in a particular stairwell. Thus, larger comer columns 108 can be utilized when a greater number of modular stair units 102 are to be stacked on top of one another.

[0058] Referring now to FIG. 9, there is illustrated a foundation support plate 902.

[0059] The foundation support plate 902 would be welded or connected in some other means to a bottom end of a corner column 108 of the lowest level modular stair unit 102 of a stairwell in area 906 indicated generally in FIG. 9. The foundation support plate 902 would be connected to the bottom end of each of the comer columns 108 and enable the base of the stairwell structure to be secured to a foundation. The foundation support plate 902 defines multiple holes 904 therein which can be used for securing the modular stair unit 102 to the foundation using bolts, screws or some other type of foundation connecting means.

[0060] Referring now to FIGS. 10 and 11, there is illustrated one side of the connection sleeve 1002. The connection sleeve 1002 is a rectangular tubular member having a size enabling the connection sleeve to be slid within the interior of the corner columns 108. On a first pair of sides 1004, the connection sleeve 102 defines a lifting eye 1006. The lifting eye 1006 enables a hook, strap, cable, etc. to be inserted therein and used for lifting a modular stair unit 102 into which the connection sleeve 1002 has been installed within a comer column 108. The associated modular stair unit 102 can be lifted into the air using the lifting eye 1006 to enable the modular stair unit to be placed upon another modular stair unit within a stairwell. Located on a second pair of sides 1108 of the connection sleeve 1002 are a plurality of leveling holes 1010. The leveling holes 1010 of the connection sleeve 1002 can be aligned with corresponding leveling holes 1012 located on the corner column 1008. The connection sleeve 1002 slides into the interior of the comer column 108 and the leveling holes 1010 are aligned with a desired leveling hole 1012 within the corner column. A bolt can then be placed through the aligned leveling holes 1010 and 1012 to maintain the connection sleeve 1010 at a desired level.

[0061] Referring now to FIG. 12, there is illustrated a connected pair of corner columns 108 using a connection sleeve 1010. As discussed previously, the connection sleeve 1002 slides within the corner columns 108. The connection sleeve 1010 is maintained at a selected height by placing a bolt 1202 through an aligned pair of leveling holes 1010 / 1012 within the connecting sleeve 1002 and corner column 108. Once the connection sleeve 1002 is secured within the lower corner column 108A, the upper corner column 108B can be lowered onto the connection sleeve 1010 and once it has been set to a desired height, a bolt 1202 can be used for securing the upper corner column 108 to the connection sleeve 1010 through aligned leveling holes 1010 / 1012.

[0062] Referring now to FIG. 13, there is illustrated a cross-sectional side view of a stair runner 1302 that interconnects a lower level to the mid-level landing 106 or the mid-level landing to the top landing 104. This can be the upper or lower stair runner as described earlier. The stair runner 1302 consists of a stringer 1304 located on each side of the stair runner to support a number of tread pans 1306. The tread pans 1306 connect to and are supported by the stringers 1304 located on each side thereof and further connect to the tread pans above and below the tread pan along the top and bottom edges. In the case of the top tread pan 1306A, this tread pan connects to the top edge 1308 of the stair runner 1302 and the tread pan immediately following the top tread pan. The tread pan 1306 includes a concrete holding well 1310 into which concrete can be poured after the stairway has been installed to provide a tread walking area for the stairway. However, it should be realized that the tread pan 1306 can be used prior to the pouring of concrete into the holding well 1310 by construction workers and inspectors. Also mounted to each side of the stringers 1304 are railings 1312 that can be of various configurations depending upon local building codes and / or construction requirements. The railings 1312 are bolted at the bottom of vertical support posts 1314 to the stair stringers 1304.

[0063] Referring now also to FIG. 14, there is illustrated a back side view of the stair runner 1302. In order to connect stair runner 1302 to either the mid-level landing 106 or top landing 104, a pair of mounting plates 1402 are connected to each of the stringers 1304 of the stair runner 1302. The mounting plates 1402 include a pair of holes 1404 therein for bolting the top edge of the stair runner 1302 to a crossbeam of the mid-level landing 106 or top landing 104. The use of bolts and the mounting plates 1402 enable the stair runner 1302 to be quickly and easily removed from or attached to the modular stair assembly 102 to enable transport to a construction site.

[0064] Referring now to FIG. 15, there is illustrated a top view of the top level landing 104. The top level landing 104 consists of it the long side members 112 interconnected with the short side members 114 using corner brackets 702. The size of the landing platform upon the top level landing 104 is adjustably configurable by movement of the support beams. Thus, as illustrated in FIG. 15, support beams 1502, 1504 and 1506 are movable in two directions as indicated generally by arrows 1508. In this manner, the platform area can be adjusted to provide more or less area as desired and can also provide for differing size stair runners running from the midlevel landing 106 to the top level landing 104. Alternatively, the platform size can be adjusted to compensate for door opening placement within the associated construction. In this manner, the top level landing 104 can be configured to fit within a number of different configurations of stair runner length and construction door openings to facilitate construction differences. The associated crossbeams 1510 within the landing can be sized to fit within the construction. While the above discussion has been made with respect to the top level landing 104, the mid-level landing 106 can be configured in a similar manner to enable for differences in size of the platform landing, differing door opening placements and differing sizes of stair runners utilized within the construction of a modular stair unit 102.

[0065] One advantage of the modular stair unit 102 configuration is that the units in both the individual and stacked configurations are self-supporting with the corner columns 108 and center columns 110 supporting the stairwell structure without any additional support from surrounding construction. In an alternative configuration, it is also possible for the modular stair units 102 to be supported by the surrounding construction rather than be self-supporting. In the alternative configuration, the modular stair units are placed and stacked upon one another as have been previously described hereinabove. However, as illustrated in FIG. 16, the modular stair units 102 can also include a plurality of Nelson studs 1602 that are welded to or connected in some other manner to the beams forming the sides of each of the top level landing 104 and mid-level landing 106. Each of the long and short beams within the top level landing 104 and mid-level landing 106 include a plurality of Nelson studs 1602 along their length. These Nelson studs 1602 would be extended into a form area 1604 that comprises a concrete form that is a part of the building structure for containing poured concrete around the Nelson studs 1604. After the Nelson studs 1602 are appropriately located within the form area 1604, the form area 1604 is filled with concrete 1606. The previously built sides 1608 of the form area 1604 and the beam of the top level layer 104 or mid-level layer 106 contain the concrete 1606 within the form area and upon hardening of the concrete enables the surrounding structure to support the top landings 104 and mid-level landings 106 without requiring the support of the comer columns 108 and center columns 110. This enables the corner columns 108 and center columns 110 to be unbolted from the top landing 104 and mid-level landing 106 and read moved from the stairwell structure. The stairwell structure remains in place due to the support of the surrounding structures provided through the Nelson studs 1602.

[0066] Referring now to FIG. 17, there is illustrated a flow diagram more particularly describing the process for building a stairwell structure that is supported by the surrounding construction rather than being completely self-supporting using support columns of the modular stair unit 102. The process is initiated in a similar manner to that described herein above wherein the modular stair system is constructed by stacking and connecting the modular stair units 102 on top of each other until the desired number of levels is achieved at step 1702. During the stacking process, each of the modular stair units 102 are positioned such that Nelson studs 1602 attached to the modular stair units 102 are appropriately located within the associated form area 1604 at step 1704. Concrete is poured at step 1706 into the associated form areas 1604 and the concrete is allowed at step 1708 to harden. Once the concrete has hardened and the surrounding structure can support the top level landing 104 and mid-level landing 106, the support columns are removed at step 1710 to allow the modular stair units 102 to be completely supported by the surrounding structure.

[0067] Referring now to FIG. 18, an enclosed modular stair unit 1800 is illustrated. The enclosed modular stair unit 1800 can include the structures describes above in regards to stair unit 102 such as stair runner 124, short sides 114, long sides 112, comer columns 108, foundation bracket 404, and top landing 104. The location of the short sides and long sides can be reversed as contemplated by the disclosed subject matter. The short sides 114 and long sides 112 can include or be defined by a connecting band. The connecting band can have a cross sectional shape such as in a “C” or “U” configuration. The channel band extends around the perimeter of the top face of the modular stair unit, as shown by FIG. 18. The system includes at least one wall 1805 connected to a surface of a respective connecting band on either the short side 114 or long side 112. The connection between the at least one wall 1805 and the connecting bands can be achieved on any surface of the connecting band, such as on a top flange surface, web, a bottom flange surface, or a side surface on the inwardly portion or outwardly facing portion of the connecting band. By connecting the walls to the side 112 / 114, the surrounding stair unit 1800 can bear all loads of the walls 1805 through the connection of the sides 112 / 114 to the comer support columns 108 including any shear forces. As such, the system according to the disclosed subject matter is self-supporting such that system is not supported by any surrounding structure such as a building. Methods and systems for connecting the at least one wall 1805 to the connecting band are described herein.

[0068] Each wall 1805 includes a top surface 1810 and a bottom bracket 1815 configured to allow for walls on one enclosed modular stair unit 1800 to be stackable. As such, the unit 1800 can be stacked onto and coupled with a lower enclosed modular stair unit 1800 at either a top portion of a wall 1805 thereof or connecting band thereof. In the embodiments describes herein, there can be a plurality of walls to enclose the stairs, such as but not limited to one, two, three, four, five, six, seven, or eight walls. Each wall can be configured to cover a portion of the side of the unit, such that two or more walls are used to cover one side of the stair unit or one wall can be used to cover the entirety of the side.

[0069] In embodiments described herein, the walls can be made of a suitable material as is known in the art. Material selection can be made as a design choice to optimize performance of the structure, such as minimizing weight, enhancing soundproofing, or meeting or exceeding a desired fire-proof rating. The walls can at least be made of constructed of wood, glass, steel, veneer, plastic, acrylic, polymer, vinyl, plywood, concrete, cement board, or gypsum. The walls can further provide the structure with a fire-proof rating in accordance with ASTM El 19-22 or equivalent (See, e.g., “ASTM El 19-22 Standard Test Methods for Fire Tests of Building Construction and Materials”).

[0070] The enclosed modular stair unit 1800, can further include a moveable connector assembly. The moveable connector assembly can be configured to connect at least one of the stair runners to a respective landing. The moveable connector assembly is configured to allow stairs and wall movement between building levels during weather activity, such as wind, or seismic activity. Further details regarding the moveable connector assembly can be found in US Pat. No. 10,968,636B2, which is incorporated herein by reference in its entirety.

[0071] In some embodiments, the moveable connector includes a first connector configured to be connected with at least one of a first stair runner 124, a first landing or a first ground location. The moveable connector assembly also includes a sliding body operatively connected with the first connector. The sliding body can include a first end and a second end such that the second end is opposite the first end. An upper connector is operatively connected with the sliding body. The moveable connector assembly can also include a lower connector. The upper connector can be operatively connected and telescopically disposed within the lower connector. A second connector can be operatively connected with the lower connector at a first connection point and can be configured to be connected with at least one of a second stair, a second landing or a second ground location.

[0072] Referring now to FIG. 19, a structure 1900 is defined by two enclosed modular stair units 1800 coupled with each other. As can be seen in FIG. 19, the bottom bracket 1815 of the top wall 1805 is stacked onto a top portion of the wall 1805 of bottom enclosed-modular stair unit. Methods and systems for connecting the at least one wall 1805 to the connecting band are further described herein.

[0073] FIG. 20 illustrates a series of steps for building a structure from a plurality of enclosed, modular stair units. Step 2001 includes providing a first and second self- supporting enclosed modular stair unit that is configured to be self-supporting. The first and second self-supporting stair units can be either the modular stair units described above with respect to FIG. 1 or FIG. 18. This structure is provided using methods previously described herein. Next, at step 2002, at least one enclosed modular stair unit is stacked onto and connected to the existing structure using the previously described methods to connect the corner supports of each modular stair unit. Additional connections are made between the top portion 1810 and the bottom portion 1815 of walls 1805 that are stacked together. Step 2002 can be repeated until the penultimate stair unit is connected to the structure. At step 2003, a top modular stair unit is stacked onto and connected to the structure. The top unit can be an enclosed or open modular stair unit in accordance with embodiments described above. FIG. 21 illustrates a structure made of several modular stair units according to several embodiments described herein. Both the open modular stair units 102 and the enclosed modular stair units 1800 are connected to other modular stair units using comer supports, the presence or absence of walls 1805 on one face or on all faces a level in the structure does not affect the self-stability of the structure and allows for different levels of the structure to be partially enclosed, fully enclosed, or completely free of walls without sacrificing any structural integrity. As can be seen in FIG. 21, some building levels can have open frames while others are enclosed. The decision to enclose a level of the structure using walls 1805 can be made by the user to allow for customization of the structure based on design needs.

[0074] Referring now to FIG. 22, the connection between a wall 1805a and the connecting bands of the sides 112 / 114 is visualized as well as the connection between walls 1805a / 1805b of different levels of the structure. Sides 112 / 114 can define a “C” or “U” cross-sectional shaped channel band 2220 that includes a plurality of sides including a top flange 2215 with an inwardly facing and an outwardly facing surface. The top of the wall 1805 can be connected to a seat plate 2210 that extends across the top surface of the wall 1805 and in some embodiments, extends outwardly from the wall 1805 as seen in FIG. 22. The seat plate 2210 is connected to the channel band 2220 at the top flange. As seen in FIG. 22, the top of the seat plate 2210 is connected to an inwardly facing surface of the top flange 2215 of the channel band 2220. This connection can be made using known methods in the art, such as mechanically with bolts, screw, or welds, or chemically with an adhesive or with other suitable methods known in the art. The wall 1805b of an upper enclosed modular stair unit can be connected to a bottom portion 1815 that can be a bracket or other supporting structure known in the art. In this embodiment, the bottom face of the bottom portion 1815 is connected to the top portion of the seat plate 2210, which defines a faying surface. A positive connection can then be made at the faying surface to connect the upper wall 1805b to the lower wall 1805. The positive connection can be at least one of a stich weld, a powder actuated adhesive, a self-tapping fastener, or another connecting methods as are known in the art. An interior wall 2225 can be connected to the inner surface of the walls 1805. The interior wall can be a gypsum board.

[0075] Referring now to FIGs. 23 A and 23B, the steps for connecting walls 1805 and the finished assembly are depicted in FIG. 23a and FIG 23B, respectively. In step 1, the channel band 2220 and the seat plate of a wall 1805 are connected as described above. In step 2, the bottom bracket 1815 that is connected to another wall 1805 by a bolt, is brought into contact at the faying surface defined by the top of the seat plate. The bottom of the bracket 1815 and the seat plate are connected by a positive connection as described above. In step 3, an interior wall, such as a gypsum board, is applied to the interior surfaces of the walls 1805. The finished assembly includes an interior wall such as gypsum board on an interior of the stair unit (also referred to as the stair core), and the walls 1805 face the exterior of building side of the structure built from the enclosed modular stair units.

[0076] Referring now to FIGS. 24A and 24B, additional connections between walls 1805 and the channel bands 2220 of the sides are illustrated. As illustrated in FIG. 24A, the channel band 2220 is disposed on the building side, external of the modular stair unit. The longitudinal side of the channel band 2220 extends further along the building side such that the top flange 2215 and the bottom flange 2230 extend in the direction away from the stair core. The seat plate 2210 of the wall 1805 extends into the space defined by the top and bottom flanges and the seat plate 2210, and is fixed to the top flange 2215 as described above. Such attachment can be made using known methods in the art, such as mechanically with bolts, screw, or welds, or chemically with an adhesive or with other suitable methods known in the art. The seat plate 2210 of the wall 1805 in this configuration is attached to the top surface of the upper flange 2215 of the channel band 2220.

[0077] Referring now to FIG. 24B, in some embodiments, the seat plate 2210 of a respective wall 1805 is attached to a respective channel band 2220 at bottom flange 2230. Another wall 1805 can then be connected at the top flange 2215 of the channel band 2220 such that a gap is defined between the top plane of a lower wall 1805 and the bottom plane of a upper wall 1805. The other wall can be a wall of a different modular stair unit, for example, or can be a different wall within the same modular unit. Multiple walls can be stacked within the same modular stair unit and can be connected at the mid-landing within the unit. Forming a gap at the mid-landing within a modular stair unit can be beneficial so that all walls have the same height same at the mid-landing. To achieve this, the seat plate 2210 of the bottom wall can extend past an outer plane of the wall into the building facing side of the modular stair unit. As described above, the seat plate 2210 is configured to be connected to the channel band using means such as mechanically with bolts, screw, or welds, or chemically with an adhesive or with other suitable methods known in the art. As seen in FIG. 24B, the seat plate is fastened to the lower surface of the channel band with bolts 2231. By facing the channel band towards the stair core side of the modular stair unit at the mid-landing, the channel band can also be used to accommodate a floor structure of the mid-landing. Such a configuration allows for a gapless connection between the two walls and the floor structure to achieve applicable fire ratings.

[0078] Steps of the methods described herein can be performed either on-site or before the modular stair units are brought onto site. For example, a set of individual enclosed modular stair units can be constructed in a factory, including the step of connecting the at least one wall to the connecting band of the stair unit. Next, all the desired modular-stair units can be shipped onto a site where the modular stair units are stacked and the connections between the corner supports and connections between the walls of different stair units of the structure are made to assembly the structure vertically. In other embodiments, the components of the stair structure can be shipped to the site and all construction steps can be performed on-site. In other embodiments, open modular stair units can be shipped to the site and walls can be selectively connected to the stair units onsite. The disclosed subject matter permits rapid construction of buildings allowing for ready to go enclosed modular stair units for incorporation into buildings, while permitting all loads attributed to the walls of the units to be absorbed by the units themselves and meeting or exceeding fire safety requirements.

[0079] In this manner, the speed of stair constructions that conform to local and national fire ratings at a commercial or residential site can be greatly increased over current construction methods. As mentioned previously, existing construction methods can take several days to completely construct stairwells within a structure that is being built and even longer to provide the necessary structure fire-proof the structure. Utilizing the above described enclosed modular stair unit, a fire-proofed stairwell can be constructed in several hours rather than several days or weeks. This provides a great cost savings due to the greatly decreased amount of time required in the construction process. The described system also increases work place safety since fire-proofed stair structures for accessing different floors in a multilevel structure are provided much earlier in the construction process and no longer the require the use of temporary measures such as ladders in order to move between building levels.

[0080] While the disclosed subject matter is described herein in terms of certain preferred embodiments, those skilled in the art will recognize that various modifications and improvements can be made to the disclosed subject matter without departing from the scope thereof. Moreover, although individual features of one embodiment of the disclosed subject matter can be discussed herein or shown in the drawings of the one embodiment and not in other embodiments, it should be apparent that individual features of one embodiment can be combined with one or more features of another embodiment or features from a plurality of embodiments.

[0081] In addition to the various embodiments depicted and claimed, the disclosed subject matter is also directed to other embodiments having any other possible combination of the features disclosed and claimed herein. As such, the particular features presented herein can be combined with each other in other manners within the scope of the disclosed subject matter such that the disclosed subject matter includes any suitable combination of the features disclosed herein. Thus, the foregoing description of specific embodiments of the disclosed subject matter has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosed subject matter to those embodiments disclosed.

[0082] It will be apparent to those skilled in the art that various modifications and variations can be made in the device, system, and method of the disclosed subject matter without departing from the spirit or scope of the disclosed subject matter. Thus, it is intended that the disclosed subject matter include modifications and variations that are within the scope of the appended claims and their equivalents.

Claims

AMENDED CLAIMS received by the International Bureau on 26 November 2024 (26.11 .2024)1. An enclosed modular stair system, comprising: a self-supporting modular stair unit that is configured to be self-supporting, wherein the stair unit includes an upper landing having an upper landing area, a pair of first members, and a pair of second members, wherein an end of each respective first member is coupled with an end of each respective second member by a respective upper comer bracket, wherein the pair of first members and the pair of second members define a connecting band, a mid-level landing having a mid-level landing area, a pair of third members, and a pair of fourth members, wherein an end of each respective third member is coupled with an end of each respective fourth member by a respective mid comer bracket, wherein the mid-level landing area is smaller than the upper landing area, a plurality of comer support columns coupled with the upper and mid comer brackets to support the upper landing and the mid-level landing, wherein the upper landing is disposed at a top of the plurality of comer support columns and the mid-level landing is disposed at a mid-portion thereof, the plurality of comer support columns removably coupled to the upper landing and the mid-level landing, a first stair runner removably coupled to the mid-level landing, a second stair runner removably coupled to the mid-level landing and the upper landing, and at least one wall coupled to the connecting band, wherein the plurality of comer support columns support the at least one wall and isconfigured to bear any load of the at least one wall, wherein the enclosed modular stair system is configured to be coupled with a second enclosed modular stair system by connecting a base of each of a plurality of comer support columns associated with the second enclosed modular stair system with the plurality of comer brackets of the enclosed modular stair system.

2. The enclosed modular stair system of claim 1, wherein the connecting band has a top flange, a web, and a bottom flange to define a “C” cross-sectional shape, and wherein the at least one wall is connected to the top flange of the channel band.

3. The enclosed modular stair system of claim 1, wherein the at least one wall comprises three walls, wherein each wall is connected to the connecting band.

4. The enclosed modular stair unit of claim 1, wherein the modular stair system has a fire rating that at least meets the requirements of ASTM El 99.

5. The enclosed modular stair unit of claim 4, further comprising a layer of gypsum board connected to an inwardly facing surface of the at least one wall.

6. The enclosed modular stair system of claim 1, further comprising a moveable connector assembly configured to connect at least one of the first stair runner or second stair runner a respective landing, wherein the moveable connector assembly is configured to allow stair and wall movement between building levels during wind or seismic activity.

7. The enclosed modular stair system of claim 6, the moveable connector further comprising: a first connector configured to be connected with at least one of the first stair runner, a first landing or a first ground location; a sliding body operatively connected with the first connector, wherein the sliding body comprises a first end and a second end, wherein the second end is opposite the first end; an upper connector operatively connected with the sliding body;a lower connector, wherein the upper connector is operatively connected and telescopically disposed within the lower connector; and a second connector operatively connected with the lower connector at a first connection point, wherein the second connector is configured to be connected with at least one of a second stair, a second landing or a second ground location.

8. The enclosed modular stair system of claim 1, further comprising: at least one seat plate configured to connected the at least one wall to the connecting band.

9. The enclosed modular stair system of claim 8, wherein the at least one seat plate comprises a faying surface on a top surface, wherein the faying surface is configured to connect at least one wall of a lower self-supporting modular stair unit to at least one wall of an upper self-supporting modular stair unit.

10. The enclosed modular stair system of claim 1, wherein the faying surface comprises at least one of a stich weld, a powder actuated adhesive, or a self-tapping fastener.

11. The enclosed modular stair system of claim 1, wherein the at least one wall is made of at least one of wood, glass, steel, veneer, plastic, acrylic, polymer, vinyl, plywood, concrete, cement board, or gypsum.

12. An enclosed modular stair system, comprising: a plurality of self-supporting modular stair units that are configured to be self-supporting, each of the plurality of self-supporting modular stair units associated with a particular level of a surrounding structure, wherein each of the plurality of self-supporting modular stair units further includes: an upper, rectangular landing comprised of a pair of first members connected at each end to a pair of second members defining a first rectangular area, wherein the pair of first members and the pair of second members each define a connecting band;a first plurality of comer brackets for connecting an end of a first member to an end of a second member; a mid-level, rectangular landing comprised of a pair of third members and a pair of fourth members interconnected at their ends defining a second rectangular area smaller than the first rectangular area; a second plurality of comer brackets for interconnecting an end of a third member with an end of a fourth member of the pair of fourth members; a plurality of comer support columns for supporting the upper, rectangular landing at a top portion thereof and the mid-level, rectangular landing at a mid-portion thereof without any support being provided by the surrounding structure, the plurality of comer support columns removably connected to the upper, rectangular landing and the mid-level, rectangular landing at the first and second plurality of comer brackets; a first stair runner removably connected to the mid-level, rectangular landing for connecting a bottom level to the mid-level, rectangular landing; a second stair runner removably connected to the mid-level, rectangular landing and the upper, rectangular landing for connecting the mid-level, rectangular landing to the upper landing; and at least one wall coupled to at least one connecting band of at least one of member of the pair of first members or the pair of second members, wherein the plurality of comer support columns support the plurality of walls and bear any load of the walls; wherein each of the plurality of self-supporting modular stair units are organized such that a bottom self-supporting modular stair unit is placed on a foundation and each successive self-supporting modular stair unit ofthe plurality of self-supporting modular stair units are stacked on top of and connected to a lower self-supporting modular stair unit by connecting a base of each of the plurality of comer support columns associated with an upper modular stair unit to a top of each of the plurality of comer support columns associated with a lower modular stair unit.

13. The enclosed modular stair system of claim 12, wherein the plurality of self- supporting modular stair units are not supported by a surrounding structure.

14. A method for building an enclosed modular stair system, comprising: providing a first and second self-supporting enclosed modular stair unit that is configured to be self-supporting, wherein each of the first and second stair units includes an upper landing having an upper landing area, a pair of first members, and a pair of second members, wherein an end of each respective first member is coupled with an end of each respective second member by a respective upper comer bracket, wherein the pair of first members and the pair of second members define a connecting band, a mid-level landing having a mid-level landing area, a pair of third members, and a pair of fourth members, wherein an end of each respective third member is coupled with an end of each respective fourth member by a respective mid comer bracket, wherein the mid-level landing area is smaller than the upper landing area, a plurality of comer support columns coupled with the upper and mid comer brackets to support the upper landing and the mid-level landing, wherein the upper landing is disposed at a top of the plurality of comer support columns and the mid-level landing is disposed at a mid-portion thereof, the plurality of comer support columns removably coupled to the upper landing and the mid-level landing, a first stair runner removably coupled to the mid-level landing,a second stair runner removably coupled to the mid-level landing and the upper landing, and at least one wall coupled to the connecting band, wherein the plurality of comer support columns support the at least one wall and is configured to bear any load of the at least one wall; and coupling the first stair unit with the second stair unit by connecting a base of each of a plurality of comer support columns associated with the second stair unit with the plurality of corner brackets of the first stair unit.

15. A method of building an enclosed modular stair system, comprising: assembling an upper landing having an upper landing area, a pair of first members, and a pair of second members, wherein the assembling includes coupling an end of each respective first member with an end of each respective second member by a respective upper comer bracket, wherein the pair of first members and the pair of second members define a connecting band; assembling a mid-level landing having a mid-level landing area, a pair of third members, and a pair of fourth members, wherein the assembling includes coupling an end of each respective third member with an end of each respective fourth member by a respective mid comer bracket, wherein the mid-level landing area is smaller than the upper landing area; coupling a plurality of comer support columns with the upper and mid comer brackets to support the upper landing and the mid-level landing, wherein the upper landing is disposed at a top of the plurality of comer support columns and the mid-level landing is disposed at a mid-portion thereof, the plurality of comer support columns removably coupled to the upper landing and the mid-level landing; coupling a first stair runner to the mid-level landing;coupling a second stair runner to the mid-level landing and the upper landing; and coupling at least one wall to the connecting band, wherein the plurality of comer support columns support the at least one wall and is configured to bear any load of the at least one wall, wherein the enclosed modular stair system is configured to be coupled with a second enclosed modular stair system by connecting a base of each of a plurality of comer support columns associated with the second enclosed modular stair system with the plurality of comer brackets of the enclosed modular stair system.

16. A method for building an enclosed modular stair system, comprising: assembling a plurality of self-supporting modular stair units, each of the plurality of self-supporting modular stair units associated with a single story of a stmcture, each of the plurality of self-supporting modular stair units further comprising a self-supporting structure supported by a plurality of comer support columns, each of the plurality of self- supporting modular stair units comprising at least one wall; locating a first self-supporting modular stair unit on a foundation of the structure; securing the first self-supporting modular stair unit to the foundation of the structure; connecting at least one wall of the first self-supporting modular stair unit to a connecting band located on a top perimeter of the first self-supporting modular stair unit; connecting at least one wall of the second self-supporting modular stair unit to a connecting band located on a top perimeter of the second self-supporting modular stair unit; stacking a second self-supporting modular stair unit on top of the first self-supporting modular stair unit, wherein a top of a first plurality of comer support columns of the first self-supporting modular stair unit engage a base of a second plurality of comer support columns of the second self-supporting modular stair unit; and connecting a bottom of at least one wall of the second self-supporting modular stair unit to a top surface of the at least one wall of the first self-supporting modular stair unit.

17. The method of claim 16, wherein connecting at least one wall of the first self- supporting modular stair unit to a connecting band located on a top perimeter of the first self-supporting modular stair unit further includes: connecting a seat plate attached to a top surface of the wall to a portion of the connecting band of the first self-supporting modular stair unit.

18. The method of claim 17, wherein connecting a bottom of at least one wall of the second self-supporting modular stair unit to a top surface of the at least one wall of the first self-supporting modular stair unit further includes: connecting the bottom surface the at least one wall of the second self-supporting modular stair unit to a top of the seat plate of the first self-supporting modular stair unit at a faying surface.

19. The method of claim 18, wherein the faying comprises at least one of a stich weld, a powder actuated adhesive, or a self-tapping fastener.

20. The method of claim 16, further comprising: applying a layer of gypsum board to an interior surface of the at least one wall of each of the plurality of self-supporting modular stair units.

21. The method of claim 20, wherein the step of applying the layer of gypsum board further comprises: achieving a minimum fire rating of ASTM E199.

22. The method of claim 16, wherein the steps of connecting at least one wall of the first self-supporting modular stair unit to the first self-supporting modular stair unit and connecting at least one wall of the second self-supporting modular stair unit to the second self-supporting modular stair unit are performed before the plurality of self-supporting modular stair units are shipped to a site; and the steps of locating a first self-supporting modular stair unit on a foundation of the structure, securing the first self-supporting modular stair unit to the foundation of the structure, and stacking a second self-supporting modular stair unit on top of the first self- supporting modular stair unit are performed on-site.

23. The method of claim 16, wherein each of the plurality of self-supporting modular stair units further comprises at least one stair runner and a moveable connector assembly configured to connect at least one stair runner to at least two landings of each of the plurality of self-supporting modular stair units, wherein the moveable connector assembly is configured to allow stair and wall movement between stories of the structure during wind or seismic activity.

24. The method claim 16, wherein the at least one wall is made of at least one of wood, glass, steel, veneer, plastic, acrylic, polymer, vinyl, plywood, concrete, cement board, or gypsum.

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