How to Build Stairs | Metal & Wood

by Omer O in Outside > Backyard

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How to Build Stairs | Metal & Wood

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How to build stairs | Metal & Wood

In this project, I am making stairs for my deck which is located at the entrance to my house.

So far, we have been using a temporary wooden pallet as a ramp for access to and from the deck.

It's finally time to create a permanent, stable, and high-quality solution.

Supplies

Materials:

  • Self drilling screws
  • Wood 14x3 cm
  • Metal Profiles 10x5 cm
  • Cement
  • Sand
  • Gravel
  • Metal bars
  • Galvanized Spray
  • Strong adhesive

Tools:

  • Welding Machine
  • Welding helmet
  • Welding gloves
  • Angle Grinder
  • Clamps
  • Ear protection
  • Impact Drill
  • Leveler
  • 90 degree ruler
  • Measuring tape
  • Wheelbarrow
  • Hoe
  • Bucket
  • Orbital sender
  • Table saw
  • Safety equipment

Planning

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The planning is based on the architectural design of the house, which defines the heights and widths of the steps, as well as their location.

(This is my sketch :))

Iron Frame

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I created the iron frame using galvanized iron profiles 10x5 cm with a thickness of 2.65 mm.

I cut the iron profiles to the desired measurements.

I cut at a 45-degree angle to maintain closed profiles along the entire length of the path.

I created three identical frames.

After finishing all welding I cleaned and painted the welds with a protective paint to prevent rust.

For the connections that were not welded (only in the corners), I applied a strong adhesive to prevent water from entering the profiles.

*I did not weld the inner corners to avoid distortions in the metal.

Installation

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To find the position for the holes in the ground, I placed the profiles above their estimated position and checked with a level and 90 angle tool that I was in the correct position.

I removed the paint from the main iron profile of the deck where I would attach the steps. (That way it will be simpler and easier to weld)

I dug holes approximately 40-50 cm deep.

I placed the profile inside the hole and attached it to the main deck profile using a large clamp.

With a level, I ensured the profile was straight, and with a 90-angle tool, I confirmed it was at a 90-degree angle to the deck, and full weld it.

I also welded two additional iron bars inside the hole in different directions to help grip the profile with concrete.

I repeated the process with the remaining two profiles, leaving the middle one for last. Before the final welding of the middle profile, I checked with an iron profile that all three profiles were in the same plane.

Concrete

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I mixed cement, yellow sand, and gravel in a bucket (which was too small and not very convenient for mixing, so I switched to a wheelbarrow, which was easier).

 The approximate mixing ratio for each hole was:

  • 2 parts cement
  • 1 part sand
  • 1 part gravel

 I slowly added water while mixing to avoid a too runny mixture.

 I filled the holes with concrete.

Wooden Cladding

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I made the step surfaces from pine wood planks measuring 14x3 cm.

I attached the planks to the iron using self drilling screws.

I made sure to leave a 5 mm space between each plank and between the planks and the iron - the gaps are important due to the wood's expansion and contraction when exposed to water.

For each step, I attached the first and last plank and then measured the distance between them.

To the missing parts in the middle I cut the desirable size on a table saw to fit the gaps.

Finishing

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Above the heads of the screws, I applied filler/sealant, after it dried, I sanded off the excess.

I will paint the wood later.

Done

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Support

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I will be happy to answer any questions.

Thank you for reading !

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Your support is much appreciated!

New projects coming soon!