DIY balusters for stairs and balustrade railings, photo and video

Balusters are vertical support posts, the main elements of the railing. Whether it's a railing for a staircase, a bridge balustrade or a veranda railing, it doesn't matter, the device and purpose are the same everywhere. From this article you will learn what balusters are and how to make them yourself.

What is a balustrade? - this is a railing of figured columns connected from above by a horizontal beam, a handrail;

Fencing posts perform several functions:

railing support;
security;
decorative element.

They can be visually divided into three parts:

handrail support;
central part;
baluster base.

The base of the baluster or pint is that part of the post that is attached to the steps or balusters. The central part performs protective and decorative functions. A handrail is installed at the upper end. This part of the post is always made with a small allowance so that you can adjust the height of the railing.

For the manufacture of a classic balustrade, both traditional materials are used: wood, metal or concrete, as well as modern analogues: glass, plastic (PVC), polyurethane.

If you know what balusters are and have seen them more than once, then you will agree that the most popular material for their manufacture is still wood. This is due to the ease of processing the material and the possibility of giving any shape.

Wooden balusters for stairs

Wooden balusters are made using three main technologies:

Stair railings consist of balusters (racks) and pillars. Entrance poles are mounted at the beginning and end of flights of stairs, as well as at the corners of the landings. They are made in the same style and differ only in height and cross section, for example, if square balusters have a side of 45 to 50 mm, then fence posts - from 80 to 100 mm. The height differs by 10-20 cm.

In accordance with GOST 25772-83, it must be taken into account that in order to ensure the safety of the operation of the stairs, the distance between the balusters must be:

stairs for the house - no more than 15 centimeters.
combined or screen railing - 30 cm.
stairs in children's institutions - 10 cm.

Flat wooden balusters

As a rule, racks in cross section have the shape of a circle or square. However, along with models of the traditional form, flat balusters are also used, which are used not only as a fence for flights of stairs, but also for gazebos, verandas, balconies and other structures.

Flat carved balusters can be installed close to each other, forming a single pattern. Thus, it is possible to perform complex ornaments of large sizes, thanks to which wooden balustrades acquire a finished appearance.

To make flat wood balusters, you need to stock up on blanks of the right size. Choose a suitable pattern and sketch. Then transfer the drawing to the workpiece and cut it out with a jigsaw along the contour.

When the ornament is sawn out, they proceed to finishing with cutters - all patterns and decorative elements are turned, made smooth and symmetrical.

What type of wood to choose?

It is very important to choose the right material, because not only the cost of the product, but also its performance characteristics will depend on this. It is recommended that the steps and pillars for stairs be made of the same wood. This will avoid deformation of the structure in the future. For the production of wooden racks, hardwoods are used.

Oak

Balusters made of oak are characterized by high wear resistance and strength, resistance to decay. The wood is dark brown or light brown in color. An important advantage is that oak balusters are not subject to cracking and do not warp. The dense structure allows you to make the smallest details and even curved elements - access to all types of balusters and methods of material processing.

Beech

Balusters made of beech are almost as hard as oak in quality and hardness, while they are easily processed and bent. Wood lends itself well to impregnation with various compositions, which contributes to a long service life of varnish and paint coatings.

The disadvantage of this type of wood is that when it dries, it warps and rots a lot, so it is recommended to use beech balusters only in rooms with low humidity. Beech is used to imitate such valuable species as walnut or mahogany.

Ash

Outwardly, ash wood resembles oak, but is inferior to it in hardness and strength. The structure is elastic, dense and heavy. Its distinguishing feature is durability and resistance to decay. Ash has a beautiful texture of yellowish color with dark and light stripes. Balusters made of ash can withstand significant loads, especially bending loads. The wood warps a little and bends well when steamed.

Birch

This tree is used somewhat less frequently than the species described above. Birch has average density, hardness and strength with good toughness. The disadvantage of birch is its tendency to crack, significant shrinkage, susceptibility to decay. But at the same time, birch is easy to process, easy to glue, polish, paint. Birch, when using appropriate dyes, is easily given the appearance of precious woods: gray maple, mahogany or walnut.

Pine balusters

Pine belongs to soft breeds, due to which it is easily processed by cutting tools and lends itself well to grinding. Pine balusters are immune to temperature changes and are resistant to fungal attack. The color of the wood varies from light yellow to yellowish red. Pine has areas with different porosity, so the paint is absorbed unevenly, which reduces the quality of the coating.

Larch

Balusters made of larch have a red-brown or brown color. This tree is inferior to oak in hardness, but surpasses it in strength, and, over time, the wood, due to the special composition of the resin, only becomes stronger. Larch is not subject to warping, but during the drying process, internal cracks may occur. Railings and balusters made of larch are durable and do not rot.

Racks can be made from rarer and more expensive types of wood that cannot be bought in a store. In this case, you should contact the manufacturer directly or a specialized company that produces custom-made balusters.

Baluster making machine

Manual frezer

Milled balusters can be cut on a homemade machine, which is shown in the photo. This requires a cylindrical workpiece.

A platform is movably mounted on a threaded shaft (1) (2 - in the figure it is in a raised state), on which, in turn, an electric drive (3) with a wood cutter (4) is fixed.

When exposed to the handle (5), the wooden blank (6) starts to rotate. At the same time, the platform moves along the shaft in a horizontal plane. As a result, a spiral line is cut on the workpiece. The depth and width of the notch is determined by the size of the cutter, and the pitch of the helix is determined by the size of the gear. Depending on the complexity of the task, the manufacture of a baluster with a manual milling cutter takes from 15 minutes to several hours.

The production of wooden balusters can be simplified by using a machine with a copier. In this case, a template is first prepared, as shown in the photo.

The essence of this method is that the depth of the cut is not adjusted manually, but with the help of a thrust-guiding roller that moves along the template. First, with the help of a roller of a larger diameter, the workpiece is roughed. Then a roller of a smaller diameter is put on and final finishing is performed. The machine for the production of balusters is shown in the figure.

A manual milling machine is mounted on a movable carriage. The cutter can move along a line perpendicular to the axis of rotation. The distance to the center of the workpiece depends on the position of the guide roller moving along the template.

When using this method, balusters and railings in general are obtained in a more complex and perfect form. CNC machines allow you to make the most beautiful specimens of any level of complexity.

Manufacturing of wooden balusters

The manufacture of wooden balusters is a complex process that requires certain skill and equipment that will ensure the rotation of the workpiece along the longitudinal axis. Most often, a lathe is used for this purpose.

The production of balusters consists of several stages.

Design

First of all, it is necessary to take into account the size of the stairs - the number of racks that need to be made will depend on this. The height of the baluster is defined as the difference between the total height of the railing and the thickness of the handrail with the step covering. As a rule, the value ranges from 65 to 100 cm.

Next, you need to decide on the design. Samples of balusters can be found on the Internet. After the sketch is selected, it is necessary to transfer it to the drawing, indicating the dimensions. In this case, all sections are numbered and the depth of the cuts is noted. For example, a drawing of a baluster of the simplest form might look like this:

All marks must be transferred to the workpiece and numbered in order to know which tool to use for a particular part.

Baluster turning

It is very important to fix the workpiece strictly in the center in order to avoid beats and distortions. If the workpiece has the shape of a square bar, then diagonals are drawn at the ends, and the baluster is fastened strictly at the point of their intersection. In this place it is necessary to make a recess.

In order for the turned balusters to have a rounded shape, sharpening is done with the help of a reyer. To simplify the process, professionals recommend first grinding off the corners, turning it into an octahedron. To do this, a cutter of the required width, located perpendicular to the axis of rotation, makes a straight cut to the required depth, and the workpiece takes on the following form:

Fastening wooden balusters to the stairs - video and photo instruction

Balusters made of wood can be installed on the steps of the stairs, or on a bowstring or kosour. For fixing, hardware, anchors (dowels) or special brackets are used. In this case, several rules must be observed:

the distance between the balusters should be no more than 150 mm;
height from 90 cm to a meter;
entry posts are installed at the beginning and end of the flight of stairs and at the corners of the site.

It should be remembered that fastening balusters with nails does not provide sufficient strength to the structure. And later causes squeaks and discrepancies in details.

Before you install the pillars on the stairs, you need to make holes in the ends, strictly in the center. To do this, you can make a simple device, consisting of a drill mounted on a chipboard shield, and a wooden block with a centering hole. To prevent the rack from staggering, a bar is used to fix its position.

This device allows you to drill even recesses in the base of the balusters, the diameter of which is 2 mm smaller than the diameter of the fastener.

Installation of balusters made of hard wood is carried out using metal studs with a cross section of 6-10 mm and a length of 60-100 mm or wooden dowels with a diameter of 8 to 14 mm and a length of 50-80 mm. Stair poles are fixed with larger fasteners.

In the example, we will use 8x100mm metal studs for the uprights and 10x100mm for the posts.

When the installation of the balusters is completed, you can attach the handrail. To do this, we cut off the upper part of the two extreme racks at the right angle, apply a rail to them and mark the place for the cut on the rest. In accordance with the markup, we saw off all the tops.

When working with a miter saw, wrap the cut with tape, so you can avoid chipping the wood.

With self-tapping screws we fasten the railing rail to the uprights, on which the handrail is subsequently mounted.

The ends of the handrail are cut so that they stand close to the posts. Niches for fasteners are cut out on the reverse side.

At the end, we fix the handrail to the railing rail with self-tapping screws and close it with a decorative overlay, cut into pieces and glued between the posts.

Metal balusters for stairs

Compared to wood, metal balusters have a number of advantages, the main of which are their durability, ease of maintenance, and the ability to use both indoors and outdoors. In addition, they look aesthetically pleasing and blend perfectly with other materials. For example, you can see combined balusters, the base of which is made of stainless steel, and the core is made of glass or wood.

Metal railings, due to the variety of forms, can become an adornment of any architectural ensemble. They are used not only as a fence for flights of stairs, but also for balconies, terraces, etc. Forged balusters for stairs look especially advantageous. Let's see what kind of metals are used:

Stainless steel

Stainless steel balusters are undoubtedly the most sought after. Benefits include:

ease of manufacture of racks. Modern methods of metalworking make it possible to make both seamless railings, made using welding, and modular, for the assembly of which hardware and brackets are used;
high anti-corrosion performance. Chrome-plated stainless steel balusters are excellent for use in environments with variable temperatures and high humidity. Such products successfully resist corrosion caused by acids, chlorine solutions, alkalis and other aggressive substances;
strength steel allows you to significantly reduce the thickness of the racks and give the whole structure a lightness and a feeling of airiness. The material does not lose its properties at low temperatures, which allows the wide use of stainless steel balusters for outdoor stairs.

Cast iron

Cast iron balusters are reliable and elegant railings for stairs. This material has its advantages:

durability. Cast iron does not lose its aesthetic and physical properties over a long period of time, while remaining beautiful and durable. It can be said without exaggeration that the staircase with cast-iron balusters is built to last;
mode of production cast iron railings (casting) allows you to make a product with the most complex configuration - any shape and content is available.
functionality. Cast iron balusters are suitable for stairs made of any material, be it wood, metal or reinforced concrete. Based on this, certain methods of fastening to the steps are used:
1. using welding or brackets for metal stairs;
2. concreting in steps for monolithic structures;
3. threaded connections or installation on a dowel for solid steps.

iron balusters

Iron lends itself perfectly to forging, which makes it possible to make beautiful railings. Often, forged balusters are made to order, which allows you to adjust the balustrade to the existing design of the room, porch or balcony. Iron is subject to corrosion, but the use of modern protective coatings provides resistance to environmental influences.

Forged balusters have only two drawbacks: high price and manufacturing complexity.

Metal processing methods

Metal balusters are made by casting or forging.

Forged balusters

For wrought iron railings, the most suitable are soft grades of iron, steel or copper. There are two processing methods:

cold forging;
hot.

In the first case, a blank is cut out of the metal, which is stamped or bent on special equipment. Further, various forging elements and decorative inserts in balusters are welded to it. The cold forging method allows you to independently manufacture simple fencing elements. The advantage of this method is its low cost, and the disadvantage is the high labor intensity of the process.

During hot forging, the workpiece is heated to a high temperature, at which the metal becomes ductile and easily acquires the desired shape. In this case, it is possible to manufacture a more perfect form of a balustrade, but this method requires deep knowledge and considerable experience in working with metal.

Cast balusters

The metal is heated to higher temperatures than forging, at which it is melted and liquid is poured into the mold. Most often, cast balusters are made of steel or cast iron. There are several types of casting:

in sandy-clay forms;
investment models;
in a chill mold;
vacuum casting and others.

The main advantage of this method is its wastelessness and the ability to make any version of the baluster of the most ideal shape, exactly repeating the workpiece.

How to DIY

To make metal racks at home, the cold forging method is used. For convenience, you can use a homemade bending machine, for example, as in the photo.

Depending on the shape of the circle, any shape can be given to the metal profile - different types of balusters are made. If the product consists of several elements, then they are connected by spot welding.

Do-it-yourself baluster installation

When installing metal racks, two main methods are used:

installation on a step- the most popular method in which anchoring of balusters is used;
at the end of the step. A more complex option, when the railings are mounted on special brackets and do not reduce the usable width of the steps;

Concrete balusters

Concrete balustrades are functional and aesthetic, they will give your home an aristocracy and elegance. Due to the qualities of the material, the product is not afraid of dampness or sudden changes in temperature. It is strong and durable.

Concrete balusters are made by pouring mortar into a mold. To make a mold, you need a model, which can be a ready-made stand made of concrete or a blank made of any other material. Such a model can be made from plaster on a simple machine (shown in the figure).

1 - handle for rotating the workpiece;

2 - baluster template;

3 - the axis on which the gypsum mixture is applied;

4 - axle mount.

The principle of operation of the machine is as follows: a gypsum mortar is fed to the rotating axis, the excess of which is cut off by the edges of the template and flows into the tray. Gypsum gradually accumulates, forming a baluster of the desired shape. After the solution hardens, the disc is scrolled several more times, cutting off the top layer. This is necessary because the gypsum expands when dried, respectively, and the size of the product increases.

The rod is pre-wrapped with paper so that the gypsum balusters do not stick and can be easily separated.

The resulting workpiece must be processed so that there are no open pores left. To do this, the surface is puttied and cleaned with sandpaper. After that, it must be primed and varnished. A model prepared in this way lasts much longer.

From the made blank, you can remove plaster, glue or cement lumpy forms.

Such a machine can be used not only for preparing models necessary for the manufacture of molds, but also directly for the production of concrete racks. How this is done is shown in the video.

First, a disk is cast, the diameter of which is approximately 5 centimeters larger than the section of the plaster model, and glued to its end, serving as a base. Further, places are marked on the disk for fractional pieces, from which the shell of the form for balusters will be formed. In these places, holes are drilled on the reverse side - these will be locks with which it will be possible to assemble the form without distortions.

The whole structure is divided in half, into two rows. Next, methodically collect the first row, as shown in the figure. All parts are lubricated with a release agent. Gypsum mortar is poured between the model and the formed board.

Forms for balusters are cast from gypsum, to which lime is added so that the material does not deform, and citric acid, so that it does not set so quickly.

After solidification, the structure is disassembled and the edges are cut. Holes are drilled on the upper part for pieces of the second row. Details are varnished and lubricated. The structure is assembled again, a side for the second sector is built, everything is smeared and filled with a gypsum solution.

Finished sectors are interconnected. For greater strength, you can still cast the outer casing in the same way as the mold itself was cast, only it is made of two halves. For ease of use, handles are inserted into it during casting. The form is ready, now you can start making the pillars.

Now in stores there are many molds made of polymers, fiberglass or other materials. Plastic molds are easy to use and durable. With their help, you can make balusters of any configuration with your own hands.

Production of concrete balusters

Our mold can be used for both casting and beating balusters. Both methods are widely used and have their own advantages.

Beating balusters

The peculiarity of the process is that the balusters are beaten using an almost dry solution. To do this, the sand is mixed with cement and aggregate in a dry form. Then they are evenly poured with small portions of water and thoroughly mixed.

You can understand that the solution is ready and meets the requirements as follows. Take a small amount of the mixture and squeeze it in your hand. If, after unclenching the hand, the substance has not disintegrated, it is ready for use.

The prepared solution is poured into the mold in small portions, in layers from 50 to 100 mm thick, and compacted well, as shown in the video. Thus, the form is filled to the very top.

Next, carefully remove the casing and pieces of the form. Be extremely careful, because the broken balusters have not yet had time to finally grab. Before complete drying, the product should not be subjected to any mechanical stress. And only in two days the rack will be ready for installation.

Rack casting

For casting concrete balusters, a mold with an upper piece in the form of a lid is used. A gypsum or concrete mortar is poured through a small hole (notch), the neck is tightly closed, and by rotating the mold in a horizontal plane, a more uniform distribution of the mortar over the vessel is achieved. After a couple of hours, the mold is disassembled and the casting is removed. By repeating the procedure, you can make the required number of racks with your own hands.

Balusters and poles made by the described methods do not require additional grinding and puttying.

Installation of concrete balusters - installation of a concrete balustrade

It is necessary to think in advance about how you will fix the balusters. To do this, metal inserts are installed in the upper and lower parts of the mold - pins 10 cm long for the bottom and 5 cm for the top. Sometimes thin reinforcement is used, passing through the entire rack.

If a concrete balustrade will be installed on a metal staircase, then this tab is simply welded to the flight of stairs. If the staircase is concrete, then it is necessary to drill holes for the anchor in the steps and, after installing the racks, fill them with mortar. The video perfectly shows how to properly install balusters and poles - make a balustrade.

Stone balusters - stone balustrades

Balusters made of natural stone are both the most beautiful and expensive at the same time. Railings made of massive pillars create a special charm of majesty and monumentality. A stone balustrade will serve as a wonderful decoration of the interior, emphasizing the luxury of the furnishings of the house and garden plot. For the production of stone balusters, the following rocks are used:

All of the above rocks are natural, and therefore expensive. What to do if you do not have enough funds to buy natural stone. There is an exit. Today, when technology has gone very far, balusters made of artificial stone have become widespread. Look at the photo below. If you think that these wonderful railings are made of natural rock, rare and very expensive. You are wrong. This stone balustrade is the result of innovative technology.

Often, non-natural material looks much better. Modern technologies are capable of many things, including imitating naturalness. The palette of colors and shades, patterns and textures will be much wider for stone balusters made in the laboratory.

This product has serious advantages over natural material:

a wide choice of colors and textures;
imitation of absolutely any natural stone;
excellent performance characteristics;
affordable price.

Artificial stone railings are resistant to aggressive substances, such as household chemicals. Therefore, in the house, such products are preferable to natural ones.

Production process

Artificial stone balusters are produced by casting, similar to concrete ones. First, a wooden blank is turned. According to it, a plaster mold is made, consisting of several parts. Inside, the surface is coated with a layer of water-repellent lubricant. This is followed by a key manufacturing step: a special solution is poured into the mold, which, after drying, will become an artificial stone. The mold is placed on the centrifuge and quickly rotated in a horizontal plane to distribute the mixture evenly. After the solution hardens, the form is disassembled. And the finished column is subjected to finishing to obtain a shine.

Glass balusters

Now more and more often various elements of stairs, including railings, are made of non-traditional materials, such as glass. Such pillars in combination with glass steps will give a special look to the stairs, creating a feeling of lightness. Glass harmonizes with all kinds of materials, from metals to plastics, which makes it possible to create combined balusters.

For production, laminated silicate glass is used, the individual layers of which are glued together by a strong polymer film. Such glass is also called building triplex. It is almost impossible to break it: the material will not withstand a strong blow, but it will not disintegrate into small fragments - cracks will only appear on it.

Glass balusters and poles are fixed with wood or metal fasteners. It can be hinges or special nozzles. Flat screens made of glass are inserted into a pre-cut groove or mounted on brackets.

Racks made of other materials

Polyurethane balusters
Inside the polyurethane shell is a metal pipe, which gives rigidity and strength to the entire structure. Polyurethane balusters are able to withstand loads no less than traditional materials. But the damaged part can be easily dismantled and replaced with a new one. Among their advantages is also ease of manufacture, speed of installation and low cost.

plastic railing
They are made of polymer plastics, which are devoid of all the shortcomings of natural materials and can imitate almost any of them, for example, wood. As a rule, high-impact polystyrene or PVC is used, the structures of which are lightweight and high strength.

Plaster balusters
Often used as templates and samples for the manufacture of racks from other materials. In appearance, they are very similar to concrete counterparts and are also produced. The main advantages are:

the possibility of implementing the most daring design decisions;
ecological purity of raw materials;
resistance to shrinkage and deformation;
light weight and ease of installation.

At the same time, gypsum balusters are durable, and if necessary, such a structure can be easily repaired.

There are other types of balusters from various materials and designs.

Conclusion

Now you know what a baluster is and what a balustrade is and are able to use the information received when buying or manufacturing these staircase elements. Do not be afraid to experiment and the result will exceed all your expectations.