loading dock stairs

Exterior Stairs – 5 Reasons Property Owners Prefer Aluminum

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More and more commercial and industrial property owners are switching from galvanized steel to aluminum exterior stairs. Here are five reasons why:

1. Long product life

Unlike steel, galvanized steel, and wood, aluminum will never rust, warp, or rot, so the structural integrity and original appearance remain intact longer than other common materials.

Explanation:

Unlike any other material, aluminum is corrosion resistant; when it reacts with oxygen in the air, a thin layer of oxide forms and naturally protects the material from elemental corrosion. The oxide layer may make the aluminum appear dull, but it does not impact the structural integrity. When damaged, the oxide layer is self-repairing and provides better adhesion for paint primers and glues than other bare metals.

Until the use of aluminum, galvanized steel was popular because it was somewhat corrosion-resistant. A protective zinc coating applied to the material in the galvanization process prevents rusting initially; however, the zinc coating eventually develops a natural carbonate on its surface from the process of atmospheric sulfur dioxide combining with rainwater, resulting in sulfuric acid – the main component of acid rain.

exterior step installation

Sulfur dioxide is emitted from the combustion of fossil fuels, which means there is a higher concentration in highly-industrialized areas (which is typically where these stairs are used) due to the high volume of vehicles. The carbonate on the surface of the galvanized steel becomes brittle and eventually splits, exposing fresh zinc that corrodes. Since the zinc coating is thin, the base metal is also often exposed and corrodes as well.

Takeaway:

In highly-industrialized areas with a high volume of freight trucks, galvanized steel experiences corrosion, while aluminum maintains structural integrity. It’s also a good ADA-compliant material for industrial walk ramps and maintenance platforms.

2. No required maintenance

Aluminum is more corrosion-resistant than any other material and does not require regular maintenance.

Explanation:

The only maintenance for aluminum stairs is to ensure that the pathway is free of snow, leaves, and other natural elements. For snow removal, we recommend a magnesium chloride ice melt because most typical ice melts are too harsh for aluminum and can damage the surface.

This is in contrast to the routine maintenance required for galvanized steel stairs which will begin to rust if the protective zinc coating is scratched. Therefore, it is recommended to routinely apply a protective coating so that the barrier between the water and the metal is maintained. Property owners have expressed dissatisfaction with this required maintenance of galvanized steel. When stairs are located in a region where it snows, removal of ice and snow can be problematic because all ice melts eat away at the zinc coating.

Takeaway:

Property owners report that steel is extremely hard to maintain, especially in climates where it rains and snows often, and aluminum is much less work.

3. Simple installation

Our product is prefabricated, requiring only a few bolts for assembly. While steel prefabricated solutions exist, aluminum is much lighter, so the aluminum exterior stairs are easier and faster to install and require less manpower.

Check out our dock step installation guide to see how easy it is. Someone without experience could assemble a dock-high stair system in a couple of hours.

Assembly Instructions for Loading Dock Step

4. Optimal strength-to-weight ratio

Aluminum meets the capacity requirements, and it’s easier than steel to install because it is lightweight.

Explanation:

Aluminum is approximately 1/3 the density of steel and weighs much less.

Upside Innovations’ distributed load is 100 lbs. per square foot with a point load of 300 lbs., the load requirements specified by the International Building Code for new construction means of egress. While galvanized steel is stronger than aluminum, aluminum exceeds the requirements for pedestrian access applications and is preferred because of its many other benefits.

5. Potentially cut costs

Property owners can save money upfront by switching from galvanized steel exterior stairs to aluminum. Typically steel stairs are manufactured by small, local companies with less capital, which means higher prices.

Explanation:

One of the world’s largest commercial real estate companies, Prologis, just changed its new construction specifications from galvanized steel dock-high steps to Upside Innovations’ aluminum dock-high steps. Switching to aluminum will save them roughly 20-30% upfront and an additional variable amount from reduced yearly maintenance costs. The cost per unit for the previously used galvanized steel stairs was high because the stairs were produced on a project-to-project basis by local, custom steel fabricators that didn’t have large-scale production capabilities. Upside Innovations has a large-scale manufacturing operation of aluminum stairs for nationwide delivery, meaning that the cost per unit is drastically lower than the aforementioned galvanized stairs.

There are instances when the upfront price of aluminum exterior stairs is not always less expensive than galvanized steel because the raw material is typically more expensive; however, the cost of aluminum stairs over the course of their life will be less because galvanized steel incurs routine maintenance costs whereas aluminum does not.

Takeaway:

Over time, aluminum has proven to be less expensive because galvanized steel requires yearly maintenance costs.

second story ada stairs

ADA Stair Landing Requirements

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This guide will help you determine the required ADA stair landing width and length to accommodate door swing and an area of refuge. We refer to the International Building Code (IBC) for new construction because it covers ADA landing requirements.

ADA Stair Landings

  • A landing must be at the top and bottom of each stairway.
  • A landing is required every 12′ of vertical stairway rise.
  • The landing should be at least as wide as the stairway that it serves. How wide does my stairway need to be?
  • The length (measured in the direction of travel) should be greater or equal to the width. For a stairway that has a straight run through a platform, the platform does not need to exceed 48″ in length.
  • The landing surface should not be sloped steeper than 1:48 in any direction.

Need an ADA stair and landing?

ADA Stair Landings with Doors:

  • Landings should be at least as wide as the stairway or the door, whichever is greater.
  • When a landing serves an occupant load of 50 or more, doors in any position should not reduce the landing size to less than 1/2 the required width.
  • When the door is fully open, it should not project more than 7″ into the required minimum landing dimensions.
ADA Stair Landings with Doors
*Required when the stairway serves more than 50 occupants

1011.6 Stairway landings – There shall be a floor or landing at the top and bottom of each stairway. The width of landings, measured perpendicularly to the direction of travel, shall be not less than the width of stairways served. Every landing shall have a minimum depth, measured parallel to the direction of travel, equal to the width of the stairway or 48 inches (1219 mm), whichever is less. Doors opening onto a landing shall not reduce the landing to less than one-half the required width. When fully open, the door shall not project more than 7 inches (178 mm) into a landing. 

ADA Stair Landings that Require Area of Refuge:

  • If the stairway requires an area of refuge, you must have a 30″ x 48″ space for every 200 occupants.
  • Access to any required wheelchair spaces in an area of refuge cannot be obstructed by more than one adjoining wheelchair space.
  • The area of refuge cannot overlap the required width of the landing.
  • The door swing cannot overlap the area of refuge.
Diagram showing Area of Refuge dimensions

Sources:

IBC Chapter 10 Means of Egress

  • 1009.3 Accessible Means of Egress: Stairways
  • 1010.1.6 Doors, Gates, and Turnstiles: Landings at Doors
  • 1011.2 Stairways: Width and Capacity
  • 1011.6 Stairways: Stairway Landings
  • 1011.8 Stairways: Vertical Rise
Warehouse stairs

New Warehouse Steps

Rust is another name for iron oxide. The process of oxidation occurs when a metal reacts with oxygen in the presence of water or moisture in the air. Given enough time and exposure to oxygen and water, any iron mass will convert to rust and disintegrate. The life of the product can be prolonged by galvanizing the metal which provides a protective layer of metallic zinc. However, galvanization often fails at seams, holes, and joints where there are gaps in the coatings. Therefore, galvanization provides protection for only a limited period of time. The chipped paint is most likely due to age, which is unavoidable.

As time goes on, the cohesive bond strength continues to develop. Cohesion, in laymen’s terms, means that the paint particles are sticking to each other better and better over time. Therefore, the cohesive bond strength can overwhelm the adhesive strength of the coating to the metal. The steps are no longer compliant with OSHA regulations since the concrete and metal have created uneven step treads along with large “lumps” in the tread nosing.

ADA-compliance is typically necessary for loading dock steps because non-affiliated delivery workers may use the steps to drop off small loads. Since the stairs are used by non-employees, ADA regulations must be followed.

Upside Innovations makes every product from aluminum because of its weather-resistant properties and high tensile strength. More benefits of aluminum are: Aluminum oxidizes when exposed to oxygen and moisture, but the result is not rust. Oxidation on aluminum actually strengthens the material instead of deteriorating it. This means that over time, aluminum becomes stronger.

The powder coating is typically applied electrostatically and then cured under heat. This makes the coating form a “skin” that is much less likely to experience the cohesion and chipping that paint experiences.

For a loading dock application, ADA-compliant warehouse steps are usually required. All of Upside’s loading dock steps are compliant with the latest ADA regulation. If ADA is not required for the application, the OSHA-compliant step is available.

Elevated walkway stairs

Aluminum Generator Access Platform

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A generator access platform and the steps are important for providing safe, compliant access to the employees who provide maintenance to generators. Platforms and steps typically comply with walking-working surfaces and OSHA regulations for fixed stairways which means that there are several regulations for tread depth, tread width, riser height, platform size, guardrail height, and more.

Rendering of an APEX generator access stairs

A generator access platform requires a guardrail system if the platform is more than 4′ above the ground or lower level. Still, for optimal safety, many employers choose a guardrail system regardless of the platform height. The guardrail system consists of top rails and midrails (or some other intermediate object between the top rail and platform). The top edge of the top rails must be between 39″ and 45″ above the walking surface, while the midrail must be installed at the midpoint between the walking surface and the top edge of the top rail.

Generator Platform OSHA-Compliant Dimensions

Typical OSHA-compliant dimensions for generator steps:

  • 6.5″ riser height
  • 11″ tread depth
  • 38″ tread width
  • 38″ clearance between handrails
  • 36″ handrail height

Read the OSHA regulations for fixed stairways to view all generator access step regulations.

Upside Innovations worked on a project involving two generators that required OSHA-compliant access consisting of platforms and steps. The end-user wanted the two generators to be connected by the platform so that maintenance personnel wouldn’t have to go up and down each generator’s set of steps. Upside designed a custom solution so that employees could access both generators via a continuous platform.

OSHA-compliant access consisting of platforms and steps
OSHA-compliant access consisting of platforms and steps
Ramp Decking Material

Modular Classroom Access – ADA Steps and Ramps

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Our team designs, manufactures, and installs ADA steps, ADA ramps, and canopies for modular classrooms. We work on all types of projects from single classrooms to large, modular school complexes.

Modular Classroom Access – ADA Steps and Ramps

Case Study:

We manufactured and installed steps, ramps, and a canopy for modular classroom access in West Virginia. The modular classrooms were a temporary solution because the original school building had water damage from the 2016 flood. FEMA helped provide resources for the school, and the organization contracted Modular Genius to supply the modular classrooms.

In total, the Modular Genius supplied 45,000 square feet of space. After installing the modular classrooms, Modular Genius purchased aluminum steps, ramps, and a canopy from us. Below are overhead images of the completed project.

In total, we supplied 10 ADA steps, 3 ADA ramps, and a walkway canopy. We installed the steps and ramps throughout the complex, so each building had ADA access. We installed the canopy over the shared walkway, which connected three of the modular classrooms together.

Ramps and steps for modular classrooms
Ramps, Steps, and Canopy provided by Upside Innovations
Orange dot = ADA-compliant steps; Black dot = ADA-compliant ramps

Check out Upside’s ADA stairs and ADA ramps.

Crossover stairs over conveyor

Crossover Metal Stairs for Industrial Applications

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Crossover Stair

Crossover metal stairs have at least two sets of stairs that are connected by one or more platforms and are designed to allow employees to safely travel up and over physical barriers in the workplace. Without stairs that provide access over the barriers, employees could be injured if they try to climb over or crawl under the object. The crossover stairs must comply with OSHA regulations to ensure that employees will not fall.

Aluminum is the most common material used for crossover steps because it is lightweight yet strong, and it won’t rust in a wet or humid environment. Steel is sometimes used, but it will rust, it is more expensive, and it’s bulkier than aluminum.

Crossover metals stairs commonly provide access over barriers such as conveyor belts, industrial pipes and ducts, and walls that don’t extend all the way to the ceiling. There are a variety of common crossover stair layouts that can accommodate a variety of barrier sizes, locations, and configurations.

Simplified Crossover Layouts:

crossover metal stairs layout
C-SHAPE CROSSOVER
crossover metal stairs layout
H-SHAPE CROSSOVER
Crossover metal stairs layout
STRAIGHT CROSSOVER
Crossover metal stairs layout
L-SHAPE CROSSOVER
Crossover metal stairs layout
Z-SHAPE CROSSOVER

The C-shape layout below was designed to help employees cross over a conveyor belt that moved materials through a small opening and into another room. The crossover platform was designed to be high enough to give enough clearance underneath so that the materials could still fit through the opening.

11221 REV-A.dft

This is the final set of crossover metal stairs installed to give access over the conveyor belt. The step risers are of equal heights, and guardrails are provided for fall-protection.


Upside Innovations will custom design a set of crossover metal stairs to meet your specifications whereas many suppliers offer a standard product that may not fit your unique application. The Upside Crossover Steps can utilize either a Grip Strut walking surface or an extruded, aluminum decking. Grip Strut is more of an aggressive tread with holes in the surface, and extruded decking is a solid surface with little raised strips for traction.

clark-associates

Trailer Stairs

Stairs for Mobile Office Trailers

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Our stairs for mobile office trailers are the best option for temporary jobs such as construction sites because they are adjustable. They are unlike other portable stairs in the market because when they adjust, they keep an even height between all treads.

The difference between our stairs and others’:

Our Omni Stairs:

Every tread adjusts at the same time, so there are even step heights.

Stairs for Mobile Office Trailers

Other stairs:

Only the bottom tread adjusts, so it will have a different height than the rest of the treads.

Stairs for Mobile Office Trailers

The stairs are fully adjustable, so they will fit on a range of heights. There are two main benefits of being able to fit multiple door threshold heights:

1) The stairs can be used for other jobs after they are no longer needed on the current site.

2) If the trailer door height is not measured correctly or the ground is sloping, our stairs will still work if the door height is within the range.

View our mobile office stair sizes.

How it works:

The video below demonstrates how the 28″ – 35″ Omni Step works. The stairs have a pivoting riser assembly that can adjust anywhere between two outer limits. Then, simply attach the stair platform to the threshold, hook the step riser onto the platform, and let the steps pivot down to the ground.

Do you need portable stairs for your mobile office?

Our Services

Our team designs, manufactures, ships, and installs ADA & IBC-compliant stairs, ramps, and canopies to fit YOUR custom project. Our experts will work with you throughout the project to ensure your installation is correct to your specifications and code-compliant.

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