One of the two interior bridges in our house will have glass decking.  The supplier of the glass decking is Sierra Glass Block, which is the distributor in Northern California for the GlassWalk system.

This feature glass decking will be one of the last components to be installed as we want to limit the number of items that could be damaged through simple accidents on our construction site (e.g., dropping a hammer).

We have been working with Terese Eiseman Keller of Sierra Glass Block and she came by our project site to review the structural steel bridge and take some photos.  Terese had not been to our site since July.

Terese Eiseman Keller, from Sierra Glass Block, taking photos of the bridge that will have the glass decking.

Our son, Nik, tested the stairs today. His younger sister, Kate, tested the stairs on the day the stairs and bridges were installed.

First, he inspected the stairs carefully, including the landing and opening to the pantry. 

Then, Nik ran up the stairs.

The stairs passed the test and received Nik’s approval.

Our son, Nikolas, takikng his first steps on our stairs.

Nik on the landing.

Today was a big day for us.  A very big day.

The team from Larson Steel (Hector, ’Little Hector’ and ‘Little Pete’) was fabulous.  They worked well with Ben, our crane operator from West Coast Crane.

Background on the Stairs and Bridges

With our atrium going through to the lower level, our bridges and stairs will be a big part of our house.  The railings will be critical as visitors will touch and feel them.

There are very few interior bridges in residential houses, so our two interior bridges will differentiate our house from many others.  Oh, we have an exterior bridge, too.

Preparing the Site

Bryan arrived at the job site at 7:25 am this morning.  It was a bit foggy.  Our crane was waiting patiently on Winchester Boulevard.  Ben, the operator, wasn’t going to move the crane into position until 8:00 am because of the loud ‘beeping’ noise it makes when backing up.

Bryan, with help from the Larson Steel team, removed the temporary safety railings.

Arriving at the job site. Note the fog - it will be a very hot day today.

Crane parked and waiting patiently on Winchester Boulevard, ready to start working at 8:00 am.

Bryan has to remove these temporary safety railings.

And, remove these temporary safety railings around the atrium.

Temporary safety railings are gone and the crane is getting set up. Still a bit of fog to burn off.

Installing the Stairs

We knew it was going to be a tight fit to put the stairs in place.  We had 1/4 inch of clearance with the feature concrete wall.  We rigged the stairs four different ways before finding the correct combination to bring it in.  Essentially, we ended up bringing the stairs in low, then raised it up and pushed it back.

Stairs being lifted from the Larson Steel truck.

Here come the stairs!

Bringing the stairs in low, then raising the stairs.

The stairs are in place!

With the stairs in place, Bryan scurried up them and helped Hector with the final adjustments.

We're done.

Placing the Bridges

The two bridges were put in place in minutes.  Literally. 

They fit perfectly and there were no issues. 

Here comes the first bridge.

Little Hector and Pete positioning the first bridge (Bridge Foyer).

Testing the bridge. Yes, it is solid. Rock solid.

Second bridge coming from the truck.

The second bridge being lowered into position (Bridge Hall).

Placing the Bridge Hall exactly where it needs to be.

Our stairs and bridges are now in place.

Done.  The crane completed its work by 9:41 and left the job site at10:00 am.

Installing the Steel Column

We installed the HSS 4×4 x 3/8″ steel column as well today.  It went in relatively fast and needed to be welded to the W6x16 steel I-beam.

Welding the steel column to the steel beam.

Threaded bars welded to I-beam for the Hardy Frames.

Our Flag is Flying Again!

Our flag is now flying - we're ready to host visitors now!

Checking in with Steve Kreck at Paramount Modular Cable Railing Systems

Bryan has been working with Steve Kreck at Paramount Modular Cable Railing Systems on the design of our railing system around the atrium and on the stairs.  Steve is great to work with and has a keen eye for detail. 

Having installed the stairs, Steve wanted to know if we had sufficient clearance for the 1×2 inch stainless steel posts on the stairs.  Bryan measured the gap and it will be close.  We’ll have to ensure the concrete doesn’t extend over the steel I-beam by the stairs or there certainly won’t be sufficient room for the posts.

There is a one-inch gap between the HSS 2x8 stringer and the W10x12 steel I-beam. Just enough for the stair posts.

You can see there is just 1/8th of an inch of clearance between the concrete wall and the stairs. Exactly as designed.

You can see the Titen bolts that hold the stairs to the concrete wall so there won't be any sway in the stairs. These bolts will be hidden behind the risers.

The same Titen bolts hold the landing to the concrete wall. It is solid. Rock solid.

You can see how the HSS 2x8 stringer on the right becomes a 3/8 inch plate that floats against the concrete wall. The same steel stringer continues all the way up the stairs on the left side.

Brittany and Jim O’Brien Inspect the Bridges

Jim and Brittany came by to see our progress.  We had dinner with the O’Briens on Saturday evening so it was great to host their visit.

Jim and Brittany O'Brien arrive at the job site.

Jim wants the Madrone decking on the bridge before going across.

Jo-Anne and Kate Test the Stairs

Jo-Anne and Kate inspected the site and tested the stairs.  They approved!

Kate and Jo-Anne arrive at the job site, ready to test the stairs.

Taking their first steps ...

It works! Jo-Anne and Kate declare the test a success.

We were very excited to see the bridges and stairs being fabricated at Larson Steel in Gilroy.  These will be extremely important features of our home so they need to be designed, engineered, fabricated and installed carefully.

HSS 5×5 with 1/2 inch Wall

Although we had some initial ideas regarding the bridge design, Hector Guerra of Larson Steel designed the structural steel components.  He recommended that we use two pieces of tube steel, 5 inches wide by 5 inches deep, with 1/2 walls.  Knowing we didn’t want any ‘bounce’ or movement in the bridges, he thought this basic structural design would work.

End of HSS 5x5, notched to sit on the W6x16 I-beam. Do you think it will be solid? Rock solid?

Bridge Foyer

This is the main bridge that goes from the foyer across the atrium to the living room.  It will be covered with Madrone hardwood flooring from the Santa Cruz Mountains.  We want this to be solid.  Rock solid.

Pete Larson inspecting the Bridge Foyer. Note the cross-pieces that will then support two layers of 3/4 inch plywood and then the 3/4 inch Madrone hardwood.

Bridge Hall

This bridge goes from the Living Room to the Master Suite.  The bridge decking will be made of glass, fritted for safety and frosted for privacy.  Importantly, using glass will allow light from the clerestory windows to go into the lower level, which will reduce the electricity required over the building’s life.

The Bridge Hall will have a separate aluminum frame in it that will hold the six pieces of 1-inch thck glass decking.

Stairs

Due to the narrow 38-1/2 inch opening between the steel column and the feature concrete wall, the stairs were a challenge to design.  We used HSS 2×8 with 3/16 wall for one stringer and, by the concrete wall, 3/8 inch plate. 

It was very rewarding to see the design coming together.

HSS 2x8 stringer components, ready for inspection prior to welding.

This is the bottom of the stairs, where the stringers will be attached together with a 3/8 inch plate. Yes, that plate will be attached securely to the concrete and then covered with 3 inches of concrete.

This is the stair stringer that goes against the feature concrete wall. The lower part (left hand side) is HSS 2x8 tube steel as we are not constrained for space at that location.

Bill Brown explained that desiging the bridges and stairs are critical to our project.  His words continue to ring in Bryan’s ears.  Especially with the rains coming.

Evaluating Bolts

Bryan went to Lord & Sons Construction Supply in San Jose on Friday and picked up some bolt samples.  We need stainless steel bolts to attach the stainless steel posts to the bridges and stairs.  These bolts will be visible and an engineering feature of our house.

There are many alternatives available, including the head design and overall profile.  This is going to require some reflection and thought in establishing the design and obtaining the look we want.

Different bolts designs and lengths. We need 1/2 inch in diameter bolts, that are 3-1/2 inches long. The bolts in this photo can be ordered in the size and material (stainless steel) that we require. The question is, 'which profile and head pattern do we want?'

We like the material (stainless steel), and the Allen key head, but don't like the profile of this bolt.

This cap head bolt looks good. It has a good surface area (important for structural strength) and we like the Allen key head. For us, this bolt has a very pleasing profile. We need this in stainless steel and 3-1/2 inches long.

The countersunk bolt looks perfect! Stainless steel and 3-1/2 inches long and we're good to go!