Stair tread and improved method of building a stairway

Abstract

A stair tread and method of building a stairway is provided. Each stair tread includes a metal pan having one or more walls forming a cavity. Concrete filler is disposed in the cavity to provide an upper walking surface. Reinforcement bars and foam blocks can be positioned within the cavity. Concrete treads including the pan can then be transported to a job site for attachment between a pair of stringers.

What is claimed is: 
     
         1 . A stair tread comprising:
 a metal pan including a bottom wall, first and second sidewalls, a front wall, and a rear wall, said walls forming a cavity;   one or more foam inserts positioned within the metal pan's cavity;   a concrete filler positioned within said metal pan which encapsulates said one or more foam inserts, said concrete filler having a top surface which is substantially planar to form an upper walking surface.   
     
     
         2 . The stair tread of  claim 1  wherein said metal pan is made of sheet metal. 
     
     
         3 . The stair tread of  claim 1  wherein each of said plurality of stair treads includes one or more reinforcing members disposed within said cavity. 
     
     
         4 . The stair tread of  claim 1  further comprising a pair of pan brackets, wherein each pan bracket is affixed adjacent to a metal pan sidewall and each of said pan brackets includes a flange that projects vertically downward. 
     
     
         5 . The stair tread of  claim 4  wherein each pan bracket flange includes a flexible tab which projects from said flange. 
     
     
         6 . A stairway assembly comprising:
 a plurality of stair treads, each of said plurality of stair treads having a metal pan including a bottom wall, first and second sidewalls, a front wall, and a rear wall with said walls forming a cavity, each of said stair treads further having one or more foam inserts and a concreter filler positioned within said metal pan's cavity, and wherein said concrete filler encapsulates said one or more foam inserts and has a top surface which is substantially planar to form an upper walking surface; and   first and a second inclined stringers positioned parallel to one another;   each of said plurality of stair treads is affixed to said first and second stringers to form a stair with said plurality of stair treads forming a stairway.   
     
     
         7 . The stairway assembly of  claim 6  wherein said first and second stringers engage and affix to each of said stair tread's metal pan's first and second sidewalls. 
     
     
         8 . The stairway assembly of  claim 6  wherein each of said plurality of stair treads includes one or more reinforcing members disposed within said cavity, said reinforcing members being encapsulated by said concrete filler. 
     
     
         9 . The stairway assembly of  claim 6  further comprising:
 a first pan bracket having a first flange, said first pan bracket affixed to said first sidewall; 
 a second pan bracket having a second flange, said second pan bracket affixed to said second sidewall; and 
 a first stringer bracket having a first slot and a second stringer bracket having a second slot, said first stringer bracket being affixed adjacent to said first stringer with said first slot receiving said first flange, said second stringer bracket being affixed adjacent to said second stringer with said second slot receiving said second flange. 
 
     
     
         10 . The stairway assembly of  claim 9  wherein said first pan bracket includes a first flexible tab which projects from said first flange, said second pan bracket includes a second flexible tab which projects from said second flange, said first stringer bracket includes an opening configured to receive said first flexible tab, and said second stringer bracket includes an opening configured to receive said second flexible tab.