Beach House
Stair Replacement
A full stair system replacement for a coastal home — from storm-damaged wooden stairs to a custom-engineered aluminum-frame structure with Douglas fir treads, designed for decades of saltwater exposure.
Deteriorated Beyond Repair
Years of saltwater exposure, sand erosion, and storm damage left the original wood stair structure beyond repair. Replacement was the only path forward.
The original stairs had been compromised after years of service — structural failure of the stringers and hardware from years of sand abuse and wood decay.
Side view showing the extent of degradation in the wooden stringers and tread supports.
Hardware corrosion and wood rot beneath the stair deck.
Hinge hardware showing years of saltwater and sand exposure.
Structural wood members split and failed at key load-bearing joints.
Designed for Longevity
The replacement was engineered in aluminum — corrosion-resistant and built for the coast. CAD was used to create the spec and visualize the look: 12 steps at 7.5″ rise, 10.25″ tread depth, 152.41″ stringer length. Douglas fir treads seat in aluminum channels.
3D isometric render — aluminum frame with Douglas fir tread layout. The modular bracket system allows each tread to be individually serviced.
Dimensioned 2D drawing. 7.5″ rise per step · 10.25″ tread depth · 152.41″ stringer length · 4″ stringer thickness.
Built in the Shop
Stringers were cut and welded to spec. Treads were pre-cut and drilled to a precise fit, bonded with 3M 4200FC and P591 primer. Nylon sleeve washers at every stainless/aluminum interface prevent galvanic corrosion.
The completed aluminum stringer assembly in the fabrication shop — all 12 tread brackets positioned and ready for treads.
P591 primer by 3M was applied at every tread-to-aluminum interface to crosslink the polyurethane adhesive to the aluminum, ensuring a long-lasting structural bond.
Douglas fir treads being fitted into the aluminum channels in the shop.
Mock-up adhesive test — treads fitted and loaded to validate bond strength before final assembly.
Shop overview with the fully assembled aluminum frame prior to tread installation.
Built to Last
Assembled in the shop and transported on a Whaler trailer, the staircase was lifted into position in one day. The original custom 316 stainless hinge hardware was reused, reconnected to the new aluminum frame to preserve the seasonal lift capability.
Fully assembled and loaded on a Whaler trailer, ready for transport.
New aluminum top plate bolted to the existing deck framing — viewed from below.
Stainless hardware with nylon washers showcased here.
The completed installation — aluminum frame and Douglas fir treads, deck to beach.
Side view from the beach.
View from the top deck.
Full view in context with the house.