Steel Pan Stairs: Musical Staircases

Steel pan stairs, also known as pan stairs or pan style, are a versatile and contemporary style of straight staircase. They are called pan stairs because their treads are like a pan or dish that will be filled, often with cement, tile, or stone. The treads are typically flanged up in the front and back to create the pan look, but if they are flanged down in the front, they can be fitted with any type of tread material. Steel pan stairs can be used as a simple staircase or as an architectural element in a home or office. They are also commonly used in steel stairs for commercial and residential buildings.

Steel pan stairs are a type of side stringer staircase

Steel pan stairs, also known as "Pan-Stair" or "Pan Style", are a versatile and contemporary type of side stringer staircase. They are characterised by their unique tread system, where the treads are formed into a pan shape to hold the fill material in place. This fill material is often concrete, but other options such as cement, tile, or stone are also used.

The side stringers in this staircase design trap the treads on the sides, allowing the treads to be set in between. The treads are typically flanged up in the front and back to create the distinctive "pan" look, although they can also be flanged down in the front to accommodate different types of tread materials.

Steel pan stairs offer a high degree of versatility in terms of shape and configuration. They can be designed as U-shaped, geometric winder treads, or even combined with curved or spiral stairs. This adaptability makes them suitable for a wide range of applications, from architectural features in homes to industrial settings like garages or decks.

One of the advantages of steel pan stairs is the durability and slip-resistance provided by the concrete fill. However, a potential drawback is the time and cost associated with field-pouring concrete, especially for larger buildings. As an alternative, pre-fabricated steel stair pans are available, offering improved efficiency in installation. These pre-fabricated pans can be customised to specific dimensions and are manufactured from high-quality sheet and plate steel.

Metal pan stair treads are formed into a pan shape to hold concrete

Metal pan stair treads are a popular choice for commercial and residential buildings. They are formed into a pan shape to hold concrete, which is poured into the pan at the construction site to create a durable and safe walking surface.

The process of creating metal pan stairs typically involves fabricating steel pan treads and attaching them to the stair stringers in a facility. Once the metal pans are in place, concrete is poured into them to form the walking surface of the stair tread. This process is known as field-pouring and is usually done individually for each stair pan.

The pans themselves are designed with a nosing, or lip, that bends up and back toward the riser, creating a concrete form and helping to contain the poured concrete. This design feature also adds a safety element to the stairs, as it can reduce the risk of slipping or falling.

Metal pan stair treads offer several advantages, including durability, slip resistance, and relatively low maintenance. They have been widely used for decades and are known for their strength and ability to withstand heavy weights.

However, there are also some drawbacks to this type of stair construction. One significant disadvantage is the cost and time involved in field-pouring concrete into individual stair pans. This process can be messy and inefficient, especially for taller buildings with a large number of stairs. Additionally, metal pan stairs can pose safety hazards during construction if temporary tread inserts are not installed, as the nosing can create a tripping risk.

Concrete-filled metal pan stairs are commonly used in commercial and residential buildings

Concrete-filled metal pan stairs are a common feature in commercial and residential buildings. This type of stair system involves a metal pan that is filled with concrete to create a durable and slip-resistant walking surface. The process typically involves pouring concrete into each stair pan individually, with each pan containing around 1.5" of concrete.

One of the key advantages of concrete-filled metal pan stairs is their durability. The concrete treads are long-lasting and provide a safe, slip-resistant surface for foot traffic. In addition, concrete-filled stairs are relatively low-maintenance and quieter than metal treads. This type of stair system has been a popular choice for decades and is often used in steel egress stairs.

However, there are also some disadvantages to concrete-filled metal pan stairs. One of the main challenges is the time and cost involved in the installation process. Field pouring concrete into individual stair pans can be messy and time-consuming, especially for multi-story buildings with a large number of stair pans. This traditional method may not align with the fast-paced demands of modern construction schedules.

Another concern is safety. The metal pans are designed with a nosing that extends up and backward, creating a potential hazard for people using the stairs before the concrete is poured. To address this issue, temporary tread inserts made of wood, foam, or other durable materials are often required, adding to the overall cost and installation time.

Despite these challenges, concrete-filled metal pan stairs remain a popular choice for commercial and residential buildings due to their durability, safety, and aesthetics.

Concrete-filled metal pan stair treads have benefits, including durability and slip resistance

Concrete-filled metal pan stair treads are a common feature in steel staircases for both commercial and residential buildings. They are formed by pouring concrete into a metal pan, creating a durable and slip-resistant walking surface. This system has been used for decades and offers several benefits that make it a popular choice for certain egress stair applications.

One of the key advantages of concrete-filled metal pan stair treads is their durability. The combination of metal and concrete provides a robust and long-lasting solution for staircases. The concrete is typically 1.5″ thick and is poured into each stair pan individually at the construction site, ensuring a sturdy walking surface.

In addition to durability, these stair treads offer slip resistance. The concrete surface provides a safe and secure footing, reducing the risk of slipping and improving overall staircase safety. This is particularly important in commercial and residential settings where heavy foot traffic is expected.

Concrete-filled metal pan stair treads also offer some level of noise reduction compared to metal treads. They are relatively quieter underfoot, which can be advantageous in certain environments, such as office buildings or residential apartments. Furthermore, concrete-filled metal pan stair treads are known for being relatively low-maintenance.

While concrete-filled metal pan stair treads offer these benefits, there are also some drawbacks to consider. One of the main cons is the cost and time associated with their installation. Field pouring concrete into individual stair treads can be a messy, time-consuming, and costly process, especially for multi-storey buildings. Additionally, it may not meet the fast-paced demands of modern construction schedules.

In conclusion, concrete-filled metal pan stair treads offer benefits such as durability, slip resistance, noise reduction, and low maintenance. However, the system also presents challenges in terms of installation time and cost. Therefore, it is essential to carefully consider the specific requirements of a project before deciding on the most suitable stair tread system.

Metal pan stairs with concrete treads are costly and time-consuming to install

The concrete must be poured individually for each stair pan, which is a slow process. Concrete finishers must often hoist the concrete up in buckets or tubs to reach each pan, which is neither efficient nor cost-effective. This method of stair construction is also messy and can create safety hazards on the job site.

To address these safety concerns, OSHA 1926.1052(b)(1) prohibits construction crews from using metal pan stairs during construction unless temporary tread inserts are installed. These inserts can be costly and time-consuming to install, and even then, crews may still use the stairs without them, resulting in safety hazards.

There are alternative tread systems available that can save time and money, such as metal diamond plate stair treads, precast concrete stair treads, and abrasive epoxy coatings over metal stair treads. These alternatives offer benefits such as eliminating field pouring of concrete, providing a non-slip surface, and being inexpensive and easy to install.

While metal pan stairs with concrete treads have been the standard for decades, they are no longer the best option for meeting the demands of modern construction.

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