FAQ
Many of the most commonly asked questions about precast stair systems, tread and handrail information and Castcon innovations are included here. But we welcome any and all additional inquiries by phone or email.
Q. What are the most cost effective riser and tread combinations we can design for our building and be sure of meeting code?
A. Castcon has existing forms for riser heights at 1/8" intervals from 6.4" risers to 7.0" with 11" treads. We also have a variety of forms with 6.0" risers with 12" treads, and 7.25" to 8.0" risers with 9.5" to 10" treads for the New York market. The steeper stairs require a variance from the code.
Q. What different types of structures can your stairs be placed in?
A. Our stairs can be placed into five different structural types: masonry load-bearing,
cast in place, precast wall, precast frame and steel frame.
Q. How do you pour your stairs?
A. Our stairs are poured upside-down, so you receive the best finish on the walking surface of the stair. We pour our stairs into a metal form, which sits overnight and is then pulled out of the form the next day. The composite landings are usually cast onto the stair the following day.
Q. What type of fire rating can be achieved with Castcon stairs?
A. We generally pour our stairs eight inches thick, which achieves a four-hour fire rating. We can pour our stairs six inches thick, which will achieve a two-hour fire rating. Our stairs can be poured up to ten or 11 inches, depending on the application and the length of the stair. Generally, the longer the run of stairs, the thicker the stair will be poured.
Q. Is there any way to protect the stair while construction is in process?
A. We do offer construction covers. These black vinyl covers are put on at the plant and cover the top of the stair completely, like a carpet runner. They are used to protect the stair from impact and damage during construction. Construction covers are removed at the site before the final walkthrough and contractors have found that they help eliminate patching the stair at the end of job. We do prefer these to be specified.
Q. How are the nosings placed on the stair?
A. We cast our nosings into the stairs. Before we pour the concrete into the forms, the nosing is placed into and attached to the steel form. We pour into the form and on top of the nosings. The next day, when the stair is taken out of the form and flipped right side up, the nosings are cleaned up.
Q. What type of metal nosing should I specify?
A. Castcon's stair forms are all steel and, therefore, the radius of the nosing is already a set dimension of 1/2". We recommend an aluminum nosing that matches the same radius so that it will fit snugly into our forms and give you the best possible alignment on the tread. We often use the Wooster Products Type 101 Alumogrit Nosing in the 3" width. It is an anodized aluminum and we coat each nosing with urethane before casting to assure that there is no reaction between the aluminum and the concrete. This way, the result is a durable, rustproof, non-slip tread. See www.woosterproducts.com for more information. Castcon also offers nosing products manufactured by American Safety Tread as an equivalent to Wooster products.
Q. How are your stairs shipped?
A. Our stairs are shipped on flatbed trucks. We generally ship about 35,000-40,000 lbs. per load. Our stairs can be shipped in 49 states within the US. Our manufacturing location is located in Saxonburg PA.
Q. What is the cost of your stairs?
A. Each stair we produce is a custom stair. We provide a price for our stairs based on the drawings we receive. If a price is ever needed, we do provide budgetary pricing at no cost within the same day, if requested. All that is needed is an elevation sketch and plan or schematic if full drawings are not available.
Q. What is the best type of handrail attachment?
A. Over many years of precasting, we have encountered almost every conceivable method of attaching handrail to precast concrete. The correct answer lies in the application. If the precast unit is for interior use only, such as a fire egress tower in an apartment or office building, the best and most economical attachment is a concrete pocket cast into the concrete which can be grouted after the handrail post is set. If the precast unit will be exposed to weathering and salts, we have found that pockets are not recommended. They can take on moisture or freeze and expand, damaging the concrete. A better choice for exterior use is a side-mounted, bolt-on application. In this detail, water is least likely to become trapped.
Q. Does Castcon erect the stairs at the jobsite?
A. Castcon is only a stair supplier and we only provide the stairs to the jobsite. Another company will erect them. We can provide you with the names of qualified erectors in most areas of the country, if necessary.
Q. How are the stairs connected to the landings?
A. Separate stairs and landings are welded together at the jobsite. Generally, there is a bearing angle that extends out from the top of the stair. This shelf-angle is welded to the plate that is embedded in the landing forming a connection. The 2” dapout is then grouted to hide the connection.