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.

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

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 :))

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.

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.

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.

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.

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

I will paint the wood later.

I will be happy to answer any questions.

Thank you for reading !

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