OH NO, Not another Staircase!

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This is a simple staircase which i'm doing for the Canadian High Commission in Trafalgar square, London.Its only one flight, and there's 8 in total with corresponding landingsSo to start we have our stringer, 300 x 20mm Profiled plate.And a nice Solid bit of beam or channel in which to make it, you don't want your stringers wavey!, Just ensure that its clamped down and you'll be guaranteed a good result.Then we set out the position of the treads as required on the drawings, This is where a protractor or digital angle finder comes in handyNote i've marked it out with white soapstone, as trying to scribe with a scriber would just mark the stringer, which is being painted. Its not too critical to worry too much about adding the threads if its out by a couple of mill, then its not noticeable,  when the staircase is finished so don't worry too much at this stage.The first Tread going onJust Tack it on both faces for now, we need to get the whole staircase complete before we start weldingLast edited by Gerry1964; 08-05-2014 at 01:26 PM.
Reply:Keep using your square and your eyes to ensure the thread is upright and levelUse a clamp to make sure the treads run true along the lenght as you keep adding moreKeep checking that the tread are on the marked lines and not crossed over, if you just keep adding and not checking then your going to have problems when you get to the end,so we've added a few and the pitches all look good, Just keep checking both front and back periodically to ensure your build is running ok
Reply:The Pitches are all within tolerance and upto our nosing line which we drew earlierOnce the tread have been added just double check that its all true and level, a view from above will highlight any issues which need resolving before the other stringer is added.OK, Now to mark out the opposite stringer, Just mark out your nosing line, in this case its 65mm and the end of the last treadYou need to make sure the stringer is clamped to the flat surface, in this case a length of channel,Last edited by Gerry1964; 08-05-2014 at 01:21 PM.
Reply:Then you need to get the other stringer on topWe're lucky we had a 3 tonne overhead crane to helpThen you simply position the stringer upto your mark and tack.Now we can start welding once we've checked our measurements and anglesNice big 6mm filletThe completed welded stringer, thats one side done
Reply:With a true straight edge, Just ensure the top is true and level and that there are no gapsYep, looking goodOnce both sides are welded then stitch weld the treads with a good 75mm fillet weld, there no need to weld right acrossThe treads all welded upOn these stairs i had to add some smaller profiles to the end of a prepped stringerand these are fully welded to the stringerand lastly the final angle going in to enable the stairs to be bolted onto the landing
Reply:heres some i made earlierand one of the landingsThe end result should be something to be proud ofIf you double check all your angles accurately then you shouldn't have any problems when they get fitted on siteand this is basically what its going to look like once its all assembledEnjoy
Reply:Wow that is some serious fab work........Looks great.......Precision TIG 185 and MP 210Bobcat 225NTCutmaster 42O/A tanks.... 2 Argon tanks...... 2 C25 TanksFacebook...... F2 Metal WorksETSY....... https://www.etsy.com/shop/F2MetalWorksF2MetalWorks.com....... http://www.f2metalworks.com/
Reply:Wow... I wouldn't know where to start on a job that size. You make it look easy. Nicely done!Miller Dynasty 200DXMiller 252 Miller 250xMiller Syncrowave 250Miller AEAD200 LegendMiller 375 Xtreme plasmaLincoln WeldPak 100Victor O/A
Reply:Thanks guys, to be honest its not a bad job to do you just need a little confidence and faith in yourself, i had a young guy on my forum about to build his first welded staircase, so i added it there just to help him and guide him in the right direction, then thought i'd add it here too for you guys.
Reply:You get all the fun jobs.......zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Originally Posted by zapsterYou get all the fun jobs.......zap!
Reply:That's going to outlast a few of us.Well done, you.Regards,RobGreat Basin WeldingInstagramBlue weldersRed weldersMy luscious Table DIY TIG Torch cooler
Reply:Nice walk thru on how it's all done and an excellent explanation of the steps it takes to get things right. It shows how careful prep is the key to things like this.To many new guys or hobbyists wonder why their projects don't look like many some of the "pro's" here do. They'd have just cut one piece and welded it in, then quickly cut the next and so on. Yours is all carefully laid out, and every piece is exactly the same, and tacked and checked. If something isn't right, or doesn't fit, you stop and fix it then, before the problems escalate. The "welding" is pretty much a minor part of the whole project. The layout, setup and prep are where all the time and care is, and it clearly shows in the finished project. Good job..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:DSW nailed it and so did Gerry in building these.  Awesome work!  Definitely built to last.  Always nice to see quality craftsmanship.
Reply:Thanks Guys for the comments  Like DSW says you just need to take it a step at a time, Check and then tack, when its complete and your happy then you can weld it up. Never be afraid of the big jobs, you just need to take your time and get it done, once you've done your first the rest is pretty much easy after that, Fabrication is basically a skill on its own, Nearly all fabricators can weld but not all welders can fabricate, so its a new challenge if your looking into doing something a little extra than just welding.You also learn silly little things that stay with you for life , for example you can't just stick a tread there and tack it because when its folded the corner of the fold on the edge of the Tread sticks out a little so if you tried to just put that on the stringer as it is it will wobble and you'll have a job to get it upright, what you need to do is grind that little point off thats caused by the bending and your thread will sit flat and upright. Just one of many different things you pick up along the journey of becoming a fabricator.
Reply:Originally Posted by 7A749Damn, Gerry. You never cease to amaze me.Being it's all in metric, I don't get it tho  Just kidding. Looks excellent bro!
Reply:Nice work indeed. Metric is where it's at guys. It's much more simple to do conversions in metric. There are only a few countries in the world today not using the metric system. The US is one of them.JasonLincoln Idealarc 250 stick/tigThermal Dynamics Cutmaster 52Miller Bobcat 250Torchmate CNC tableThermal Arc Hefty 2Ironworkers Local 720
Reply:Gerry1964 - As one of the less experienced guys on here, I learned a lot from your thoughtfully documented post.  The quality of the workmanship that you put into every step of this fabrication, and your comments along the way, form something that I consider a sort of gold standard.   I hope that I won't again be as casual as I have been about ignoring DSW's "The welding is pretty much a minor part of the whole project."       -Marty-
Reply:Just been to the Canadian High Commission in London and have seen some of my staircase going up  Give me a few minutes to settle down and i'll post some pictures, and before you ask, Yes i work Sundays Too!!
Reply:Ok here goes with some Pictures....One of the flights ready to go on the back of the truck, This one weighs about 1.5 ton, so pretty heavyArriving at the site of the Canadian Embassy, Everything has to go via the side door, lucky we had a hoist to get it off the truckLast edited by Gerry1964; 09-01-2014 at 05:43 PM.
Reply:Don't think the traffic was impressed with barriers going up in the road as we tried to push the staircase inand finally through the side doorOnce inside you can start to see how large this build actually is
Reply:Nice to see the flights and landings coming together
Reply:All in all theres 8 flights and and half landings over 4 floorsOne of the 10 inch support columns with full penetration weld all round.
Reply:It was a bit dusty there that morning and i was taking these pictures with my phone, so the quality isn't that greatA close up of one of the column welds, note the 20mm strongback which is temporarily welded to the tube to keep it straight, these are removed once the weld has cooled downOne of the half landing ready to slide down one of the columnsThe 4th Flight now being raised up via block and tackle
Reply:So thats it for now, It was great driving to London on a sunday, the sun was shining and a lot less traffic, Even old Lord Nelson, in Trafalgar Square had a smile on his faceand the Tower of Londoneven London Bridge and St Pauls Cathedral, were all on the wayWhat coating are you using for non skid. I would think just paint would be murder when your shoes are wet. I have built several sets of steps and that was good work you showed. Mine have been single story w/landing steps and I used the pre-bent stair pans and filled them with concrete for non skid.
Reply:Originally Posted by mwshawWhat coating are you using for non skid. I would think just paint would be murder when your shoes are wet. I have built several sets of steps and that was good work you showed. Mine have been single story w/landing steps and I used the pre-bent stair pans and filled them with concrete for non skid.
Reply:Wow! the project is incredible!I want to know more about the truck body.
Reply:The last time I was in London, I remember asking the driver that picked us up at the Airport if he knew where a good industrial supply/tool and equipment shop was and he looked at me like I was an alien.  I always seek a visit to a place like this when traveling.  I'd love to do a tour of folks work shops.  I usually, bring back a tool or instrument. No such luck in London.  I saw lots of the usual stuff and had some great meals.  We need an exchange program/work shop tour swap for our international travelers/members!Thanks for the Pics.
Reply:Originally Posted by Willie BWow! the project is incredible!I want to know more about the truck body.
Reply:OK Guys been a while since the last Update, been busy working on 3 different sites in London, But i have some pics of the Canadian Embassy Staircase and its looking good, Please forgive the bad shots as they were taken with my phone...Steelwork now primed and sprayed The Glass balustrade is covered in Brown paper to protect it from the spraying The Landing Glass returns are all set to take the glass
Reply:Here you can see some of the glass already fittedAnd the wood on the risers, the top of the step is protected with some MDFLast edited by Gerry1964; 10-07-2014 at 01:04 PM.
Reply:and close up of completed step with the wood and stainless edgeTheres a slight gap 2mm each end of the wood to the stringers, this will be filled with black silicone to allow the stairs to contract or expandThats it so far guys, will post some more when completed
Reply:Ok Its been a while, so here's an update
Reply:Wow! That is just awesome!GravelThe difference between theory and practice is that in theory there is no difference.
Reply:Nice work Gerry!SqWave 200Millermatic 190Airco 200 ACHypertherm PM45Boice-Crane Band SawVictor O/A
Reply:Ok These are the Finished Stairs and Been busy making some other staircases but this one has to be my Fave by far, So if any of you guys ever go to the Canadian Embassy in London at least you'll know who made those stairs!!
Reply:Beautiful!
Reply:Stunning, Gerry.You must get tired of climbing stairs.  When I was about 18 I had a summer job in construction.  I was a gofer/helper for the job super on a 14 story building.  It was up about 10 floors or so when I was working, no elevators yet.  I got darned tired of running up and down all day."USMCPOP" First-born son: KIA  Iraq 1/26/05Syncrowave 250 w/ Coolmate 3Dialarc 250, Idealarc 250SP-175 +Firepower TIG 160S (gave the TA 161 STL to the son)Lincwelder AC180C (1952)Victor & Smith O/A torchesMiller spot welder
Reply:Amazing!Just a couple welders, big hammers, grinders, and torches.Work will free you.Men in dirty jeans built this country, while men in clean suits have destroyed it. Trump/Carson 2016-2024
Reply:Fantastic!Regards,RobGreat Basin WeldingInstagramBlue weldersRed weldersMy luscious Table DIY TIG Torch cooler
Reply:Originally Posted by Mick120I love the way you started this thread by saying...."Some simple stairs"......They are sensational.
Reply:Take it a step at a time... there's many steps there mate at  heights! Awesome work
Reply:Gerry,Wow, that finished product really pops between the wood and paint choice. It really showcases your excellent craftsmanship!! I have built a few measley multi-level light commercial/residential stringers and landings in the past. Just generic though.. clips, decking and concrete; nothing like this beautiful structure that you've created.  The description that you and others have said describing the slow, methodic measures to keep everything perfectly PPP along the way makes a lot of sense. I am a hundred miles a minute compared to a lot of people and have much room for improvement in doing things slow and methodical when it comes to creating. I have looked at a lot of projects on here for a good while before I actually registered. The apparant craftsmanship and humbleness that you and others on this board exhibit inspires me to do a better job in my own work. Thanks for sharing. -Niche
Reply:Originally Posted by NicheFabGerry,Wow, that finished product really pops between the wood and paint choice. It really showcases your excellent craftsmanship!! I have built a few measley multi-level light commercial/residential stringers and landings in the past. Just generic though.. clips, decking and concrete; nothing like this beautiful structure that you've created.  The description that you and others have said describing the slow, methodic measures to keep everything perfectly PPP along the way makes a lot of sense. I am a hundred miles a minute compared to a lot of people and have much room for improvement in doing things slow and methodical when it comes to creating. I have looked at a lot of projects on here for a good while before I actually registered. The apparant craftsmanship and humbleness that you and others on this board exhibit inspires me to do a better job in my own work. Thanks for sharing. -Niche