Modular Stair System Using Connection Sleeves for Rapid Assembly
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Solution Overview
Problem
The construction of stairs in multilevel structures is a time-consuming process that delays access between levels, often requiring unsafe temporary methods like ladders, necessitating a quicker and safer method for building stair structures in residential and commercial construction.
Innovation Solution
A modular stair system comprising self-supporting units with corner columns and connection sleeves allows for rapid assembly by stacking and securing modular units, enabling the construction of stairwells in hours rather than days, with the ability to be erected before surrounding construction is completed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional stair construction methods are used, then structural integrity is ensured, but construction time is excessively long (several days)
Solution Approach 1:
The stair structure is divided into modular units that can be pre-assembled and then stacked quickly on-site. Each module contains standardized components (stringers, treads, risers, landings) that can be independently manufactured and rapidly assembled using connection sleeves and corner columns, reducing construction time from days to hours.
Solution Approach 2:
Stair modules are pre-assembled and pre-leveled at the manufacturing facility before transportation to the construction site. This preliminary assembly includes pre-attaching connection sleeves to corner columns and pre-leveling modules, allowing for rapid installation without time-consuming on-site assembly operations.
2Reliability
If stairs are built as part of the completed structure, then structural stability is maintained, but access between levels is delayed requiring unsafe temporary methods
Solution Approach 1:
The modular stair system enables construction of safe, permanent stairways before surrounding building work is completed. Modules are pre-assembled with all necessary structural components and connection mechanisms, allowing them to be installed as self-supporting units that provide immediate safe access between levels during construction.
Solution Approach 2:
The design incorporates built-in support mechanisms including corner columns, connection sleeves, and optional temporary support columns that ensure structural stability from the moment of installation. This eliminates the need for unsafe temporary ladders by providing a cushioned, safe transition path between levels from the outset.
3Productivity
If modular units with connection sleeves are used, then assembly speed is increased, but connection precision and leveling accuracy must be maintained
Solution Approach 1:
The connection sleeve design incorporates leveling mechanisms that allow upper modules to be leveled relative to lower modules during assembly. The sleeve acts as a reference plane, enabling workers to use simple leveling tools to ensure proper alignment and horizontal positioning, maintaining precision without slowing down the rapid assembly process.
Data Source
AI summary
A method for building modular stair system comprises assembling a plurality of modular stair units, each of the plurality of modular stair units associated with a single story of a construction, each of the plurality of modular stair units further comprising a self-supporting structure supported by a plurality of corner columns. A first modular stair unit is located on a foundation of a structure. The first modular stair unit is secured to the foundation of the structure. A second modular stair unit is stacked on top of the first modular stair unit, wherein a first plurality of corner support columns engage of the first modular stair unit engage a second plurality of corner support columns of the second modular stair unit. The second modular stair unit is leveled using a connection sleeve that slides within the first plurality of corner support columns and the second plurality of corner support columns. The second modular stair unit is connected to the first modular stair unit to maintain the leveled second modular stair unit using the connection sleeve.