Modular Cantilever Stair Assembly for Precision-Free Installation
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Solution Overview
Problem
The construction of cantilever stairs often requires builders to install temporary stairs during construction, which are then removed and replaced with permanent stairs, a process that is time-consuming and costly, and previous methods demand high precision to avoid errors and rework.
Innovation Solution
The proposed solution involves a cantilever stair assembly that can be installed in segments using separately installed stair tread modules, which reduce the need for precise alignment and minimize potential errors, allowing for a single installation at the location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a steel plate connects to studs running the length of the stairs, then the stairs have structural support, but precision within 1/16 inch over the entire length is required
Solution Approach 1:
The stair assembly is divided into separate modular components: individual stair treads, support brackets, and mounting hardware. Each module can be manufactured independently with standard tolerances and assembled on-site, eliminating the need for continuous precision alignment over the entire stair length.
Solution Approach 2:
Support brackets are pre-assembled with mounting holes and alignment features before installation. The brackets are manufactured with precision in a controlled factory environment, then installed as pre-positioned elements that guide subsequent stair tread placement, reducing field alignment requirements.
2Reliability
If temporary stairs are installed during construction, then wear and damage are absorbed, but additional time and effort are required for installation and removal
Solution Approach 1:
The permanent stair modules are designed and prepared in advance with all necessary components (treads, brackets, fasteners) ready for installation. This preliminary preparation allows the stairs to be installed as a single permanent solution rather than requiring temporary structures during construction.
Solution Approach 2:
The stair module design incorporates features that facilitate self-support during installation, with brackets that can be mounted to structural members independently, and treads that interlock or secure in place without requiring temporary support structures.
Data Source
AI summary
A cantilever stair assembly for installation in segments or sections includes a stair tread module including a stair tread plate having a tread hole. An embedded stair tread is inserted into and fixed within the tread hole. The stair tread module may include a first inner wall stair tread support and a second inner wall stair tread support for mounting to opposite sides of a vertical support member. Each of the first and second inner wall stair tread supports has a first plate with a plurality of support-member-engagement holes therethrough and a second plate perpendicular to the first plate and having a plurality of stair-tread-plate-engagement holes therethrough. The stair tread plate is secured to at least one of the plurality of stair-tread-plate-engagement holes of each of the first and second inner wall stair tread supports.