Thanks to many different issues conspiring against a timely build (cashflow, lack of help, disappearing subs, etc., etc.) things have been creeping along at the lightBOX project. Even so, things have been getting done. The biggest bit of progress has been made on the exterior steel stairs and handrails.
We started by laying out and pouring the concrete foundations for the landing and the bottom step. Four 8" sono-tube footings anchor the landing and a 3'x 12" bottom step anchors the lower stringers.
Next came setting the steel structure for the landing, which was fabbed up in the shop and then bolted to the concrete footings.
We then started fabbing up the landing platform and the stringers in our shop. The stringers are composed of 4" structural channels with 2"x 1/4" hairpin steel risers that will support the treads. The hairpin risers were cold bent using a classic Hossfeld Universal Bender. After 2 hours of getting the bends jigged up right, the 48 seperate pieces were bent in about 15 minutes. You got to love mechanical advantage.
We then did a full scale layout, figuring out the proper riser spacing by laying out the as-built measurements of the landings and existing structure at full scale on the shop floor. This allowed us to get everything just right in the shop, so that everything fit perfectly when installed on site.
After installing the landing and stringers, came the installation of the handrail panels. These too were fabbed in the shop, based on full scale layouts of the as-built condition. Composed of 1 1/2" square tubing, they will eventually be infilled with welded wire mesh and sections of wood slats.