Barrier and Handrail System.

Building Your Handrail System.

All Fittings Fit Our Standard 42mmØ
Galvanised Tubing.
For Any Other Sizes, Please Phone Pear Stairs
On 01938 553311.

This is barrier and handrail system.

We have sold systems for many variety of situations. These include:

Safety barriers.
Gates.
Shelving.
Stairway handrails.

There are many more examples.

Below are case studies to help you choose the correct fittings for any situation. Please phone Pear Stairs on 01938 553311 if you have any questions. Our friendly staff will be only too willing to help.

Case Study 1 - Base and Wall Fixings.

base and wall fixings

This handrail system was created as a safety barrier to prevent accidental falls from the elevated platform. It was secured using both base flange (Item 7) and vertical side supports (Item 8).

	Short Tee.
1.			90° butt joint, often used to join intermediate uprights to top rails and middle rails to end uprights on levels.

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	Cross (Middle Rail).
2.			90° joint, often used between middle rail and uprights on level sites. The through tube (vertical in photo) cannot be joined within the fitting.

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	Corner (Top Rail).
3.			90° corner joint, often used where top rail meets corner upright on level sites.

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	Corner (Middle Rail).
4.			90° corner joint, often used on middle rail on level sites. The through tube (vertical in photo) cannot be joined within the fitting.

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	90° Elbow.
5.			90° angle joint, often used where top rail meets end upright on level sites.

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	Long Tee.
6.			90° joint, often used to join intermediate uprights to top rails on level sites.

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	Railing Base Flange.
7.			Base flange, usually used for uprights on level sites. Fixing holes suit a wide range of common mechanical and chemical masonry anchors which we should be pleased to quote for on request.

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	Side Support (Vertical Base).
8.			A palm-type fitting, often used to attach guardrail uprights to walls, staircases and ramps. In standard form, the tube cannot pass through the bottom of the fitting, although the fitting may be modified to accommodate this at extra cost.

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Setscrew.

Please Note: All fittings are supplied with setscrews fitted as standard.

High quality setscrews, a vital component in the high structural integrity of the fittings.

Thread : 3/8"
Alan Key Size : 5/16"

N.B. All fittings are supplied with setscrews fitted as standard. But you can purchase additional setscrews if required. Also note you can purchase a security set screw in our online shop also, along with security fix hex key.

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Hexagon Keys.

High quality imperial size hexagon keys.

Size: 5/16"

Note: You can purchase a security alan key along with a security set screw.

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	Handrail/Tubing.
c.		Galvanised Medium Weight tube to BS EN 10255 (formerly BS1387). Ø : 42.4mm We sell 3 metre lengths of galvanised tubing, you can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

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Case Study 2 - Gate System and Wire Mesh Panels.

gate system and wire mesh panels

This structure is used to guard pedestrians from accidently straying from the pathway into the maintenance route for some sluice gates. The railing system also contains a gate which can be used for access by maintenance staff.

Mesh Panel.

Manufactured to order on request to suit customer's requirements, mesh panels are supplied welded to an 8mm rod frame and are available in common mesh sizes e.g. 50x50mm, 25x25mm and 50x25mm. Bent corner panels are available on request.

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	Single Mesh Panel Clip.
2.			For attaching mesh panels to one side of tube. N.B. This item is manufactured from steel, not malleable iron. Designed to suit 8mm rod.

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	Gate Hinge Pin.
3.			Often used with gate eye to form gate hinges. The tube cannot be joined within the fitting.

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	Gate Eye.
4.			Often used with gate eye hinge pin to form gate hinges. The tube cannot be joined within the fitting.

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Setscrew.

Please Note: All fittings are supplied with setscrews fitted as standard.

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Hexagon Keys.

High quality imperial size hexagon keys.

Size: 5/16"

Note: You can purchase a security alan key along with a security set screw.

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	Handrail/Tubing.
c.		Galvanised Medium Weight tube to BS EN 10255 (formerly BS1387). Ø : 42.4mm We sell 3 metre lengths of galvanised tubing, you can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

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Case Study 3 - Handrail System.

handrail system

Our range of handrail systems can be constructed easily using a variety of connecting parts. These parts can be combined to forge a handrail system as exampled above, a pedestrian guardrail.

	Short Tee.
1.			90° butt joint, often used to join intermediate uprights to top rails and middle rails to end uprights on levels.

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	Long Tee.
2.			90° joint, often used to join intermediate uprights to top rails on level sites.

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	Cross (Middle Rail).
3.			90° joint, often used between middle rail and uprights on level sites. The through tube (vertical in photo) cannot be joined within the fitting.

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	90° Elbow.
4.			90° angle joint, often used where top rail meets end upright on level sites.

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	Railing Base Flange.
5.			Base flange, usually used for uprights on level sites. Fixing holes suit a wide range of common mechanical and chemical masonry anchors which we should be pleased to quote for on request.

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Setscrew.

Please Note: All fittings are supplied with setscrews fitted as standard.

To look at purchasing this item click this button.

Hexagon Keys.

High quality imperial size hexagon keys.

Size: 5/16"

Note: You can purchase a security alan key along with a security set screw.

To look at purchasing this item click this button.

	Handrail/Tubing.
c.		Galvanised Medium Weight tube to BS EN 10255 (formerly BS1387). Ø : 42.4mm We sell 3 metre lengths of galvanised tubing, you can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

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Case Study 4 - Stairway.

This installation shows a two tier stairway system. This simple system uses several different parts which interconnect to create a safe environment to ensure the easy flow of several thousand people. The vertical posts have simply been concreted into the ground, no ground mountings were used.

	Short Tee.
1.			90° butt joint, often used to join intermediate uprights to top rails and middle rails to end uprights on levels. This clamp cannot be used where through tube (horizontal in photo) has to be joined within the fitting.

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	Cross (Middle Rail).
2.			90° joint, often used between middle rail and uprights on level sites. The through tube (vertical in photo) cannot be joined within the fitting.

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	Variable Elbow (15° - 60°).
3			Variable 15° to 60° angle joint, often used to join staircase top rail to end uprights.

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	90° Elbow.
4.			90° angle joint, often used where top rail meets end upright on level sites.

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	Double Swivel Connection.
5			A versatile swivel fitting, useful for awkward applications where angles cannot be accommodated by adjustable angle fittings.

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	Single Swivel Connection.
6.			A versatile swivel fitting, useful for awkward applications where angles cannot be accommodated by adjustable angle fittings. The through tube (sloping in photo) cannot be joined within the fitting.

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Setscrew.

Please Note: All fittings are supplied with setscrews fitted as standard.

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Hexagon Keys.

High quality imperial size hexagon keys.

Size: 5/16"

Note: You can purchase a security alan key along with a security set screw.

To look at purchasing this item click this button.

	Handrail/Tubing.
c.		Galvanised Medium Weight tube to BS EN 10255 (formerly BS1387). Ø : 42.4mm We sell 3 metre lengths of galvanised tubing, you can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

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Case Study 5 - Ramp Access System.

ramp access system

The example above is an access ramp used to reach a garage which is above ground level. Again, a simple design which utilizes nine different parts to construct the guarded ramp system.

	Short Tee.
1.			90° butt joint, often used to join intermediate uprights to top rails and middle rails to end uprights on levels. This interclamp cannot be used where through tube (horizontal in photo) has to be joined within the fitting.

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	90° Elbow.
2			90° angle joint, often used where top rail meets end upright on level sites.

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	Plastic Stop End.
3.		Plastic stop end.

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	Handrail Wall Bracket
4			Often used to attach to walls as a position wall fixing for structures, or to attach kick plates to uprights. The tube cannot be joined within the fitting.

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	Side Support (Vertical Base)
5.			Often used to attach to walls as a position wall fixing for structures, or to attach kick plates to uprights. The tube cannot be joined within the fitting.

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	Combined Tee & Crossover
6.			Often used in racking and similar structures, the fitting allows both uprights and front and rear horizontal rails to be continuous. It is usually preferable for the upright to be on the outside of the structure (a per the photo) for maximum stability. The trough tubes cannot be joined within the fitting.

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	Double Swivel Connection.
7.			A versatile swivel fitting, useful for awkward applications where angles cannot be accommodated by adjustable angle fittings.

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	Single Swivel Connection.
8.			A versatile swivel fitting, useful for awkward applications where angles cannot be accommodated by adjustable angle fittings. The through tube (sloping in photo) cannot be joined within the fitting.

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Setscrew.

Please Note: All fittings are supplied with setscrews fitted as standard.

To look at purchasing this item click this button.

Hexagon Keys.

High quality imperial size hexagon keys.

Size: 5/16"

Note: You can purchase a security alan key along with a security set screw.

To look at purchasing this item click this button.

	Handrail/Tubing.
c.		Galvanised Medium Weight tube to BS EN 10255 (formerly BS1387). Ø : 42.4mm We sell 3 metre lengths of galvanised tubing, you can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

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Case Study 6 - Disabled Ramp Access.

The above example is a handrail system to assist disabled users to move up a ramp.

This system is ingenious as it only uses six parts and a simple hexagon key is used to tighten the setscrews. This system, like all our parts, requires no welding, threading or riveting so no special equipment is needed.

Further instructions on how to assemble a system to assist disabled users can be found in our section 'Building Your Handrail System - DDA Assist Installation Guide'.

	Short Tee.
1.			90° butt joint, often used to join intermediate uprights to top rails and middle rails to end uprights on levels. This clamp cannot be used where through tube (horizontal in photo) has to be joined within the fitting.

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	90° Elbow.
2			90° angle joint, often used where top rail meets end upright on level sites.

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	Railing Base Flange.
3.			Base flange, usually used for uprights on level sites. Fixing holes suit a wide range of common mechanical and chemical masonry anchors which we should be pleased to quote for on request.

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	Assist Elbow.
4.			90° elbow.

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	Assist Internal Swivel Bracket.
5.			To attach handrail to an upright at any angle when used in conjunction with 90° elbow.

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	Assist O-Ring (Optional).
6.		An optional extra to be fitted to each end of the expanding assist fittings, to attain the best finish.

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	Aluminium Stop End.
7.		An optional extra to be fitted to each end of the expanding assist fittings, to attain the best finish.

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Setscrew.

Please Note: All fittings are supplied with setscrews fitted as standard.

To look at purchasing this item click this button.

Hexagon Keys.

High quality imperial size hexagon keys.

Size: 5/16"

Note: You can purchase a security alan key along with a security set screw.

To look at purchasing this item click this button.

	Handrail/Tubing.
c.		Galvanised Medium Weight tube to BS EN 10255 (formerly BS1387). Ø : 42.4mm We sell 3 metre lengths of galvanised tubing, you can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

To look at purchasing this item click this button.

Case Study 7 - Wall Mountings.

This example is a staggered queue system with a ramp leading into access to a public toilet (including disabled facilities).

	Wall Flange.
1.			Positional fixing flange which is often used where rails meet walls on level sites.

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	Short Tee.
2.			90° butt joint, often used to join intermediate uprights to top rails and middle rails to end uprights on levels. This clamp cannot be used where through tube (horizontal in photo) has to be joined within the fitting.

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	90° Elbow.
3.			90° angle joint, often used where top rail meets end upright on level sites.

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	Side Palm.
4.			A palm-type fitting, often used to attach guardrail uprights to walls, staircases and ramps. In standard form, the tube cannot pass through the bottom of the fitting, although the fitting may be modified to accommodate this at extra cost (with loss of use of bottom bolt hole).

To look at purchasing this item click this button.

Setscrew.

Please Note: All fittings are supplied with setscrews fitted as standard.

To look at purchasing this item click this button.

Hexagon Keys.

High quality imperial size hexagon keys.

Size: 5/16"

Note: You can purchase a security alan key along with a security set screw.

To look at purchasing this item click this button.

	Handrail/Tubing.
c.		Galvanised Medium Weight tube to BS EN 10255 (formerly BS1387). Ø : 42.4mm We sell 3 metre lengths of galvanised tubing, you can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

To look at purchasing this item click this button.

Case Study 8 - Pedestrian Barrier.

pedestrian barrier

This is an example of a coastal pedestrian barrier, using our galvanised range of tubing.

Constructed to protect the public from accidental fall into the sea.

The pedestrian barrier panel (2) dimensions can be constructed based on customer requirements.

	Long Tee.
1.			90° joint, often used to join intermediate uprights to top rails on level sites.

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Pedestrian Barrier Panel.

To provide rapid construction of pedestrian control structures 12mm solid vertical bars. To improve visibility for drivers through the barriers, the bars are staggered. The barriers meet the infill requirements of Sections 2.4.1 and 2.4.2 of BS7818:1995 (Pedestrian Restraint Systems in Metal).

Available Only On Request.

Please phone Pear Stairs on 01938 553311

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	Cross (Middle Rail).
3			90° joint, often used between middle rail and uprights on level sites. The through tube (vertical in photo) cannot be joined within the fitting.

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	Railing Base Flange.
4.			Base flange, usually used for uprights on level sites. Fixing holes suit a wide range of common mechanical and chemical masonry anchors which we should be pleased to quote for on request.

To look at purchasing this item click this button.

Setscrew.

Please Note: All fittings are supplied with setscrews fitted as standard.

To look at purchasing this item click this button.

Hexagon Keys.

High quality imperial size hexagon keys.

Size: 5/16"

Note: You can purchase a security alan key along with a security set screw.

To look at purchasing this item click this button.

	Handrail/Tubing.
c.		Galvanised Medium Weight tube to BS EN 10255 (formerly BS1387). Ø : 42.4mm We sell 3 metre lengths of galvanised tubing, you can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

To look at purchasing this item click this button.

Case Study 9 - Softplay Area.

This indoor play area is constructed using a variety of connecting parts. Multi-directional and multi-angled parts are utilized to create the maze like structure. Foam padding and string mesh (by others) are easily incorporated into the structure to prevent injury.

	Short Tee.
1			90° butt joint, often used to join intermediate uprights to top rails and middle rails to end uprights on levels. This clamp cannot be used where through tube (horizontal in photo) has to be joined within the fitting.

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	Corner (Middle Rail).
2			90° corner joint, often used on middle rail on level sites. The through tube (vertical in photo) cannot be joined within the fitting.

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	Cross (Middle Rail).
3			90° joint, often used between middle rail and uprights on level sites. The through tube (vertical in photo) cannot be joined within the fitting.

To look at purchasing this item click this button.

	90° Elbow.
4.			90° angle joint, often used where top rail meets end upright on level sites.

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	Corner (Top Rail).
5			90° corner joint, often used where top rail meets corner upright on level sites.

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	Adjustable Cross (Middle Rail)
6			90° corner joint, often used where top rail meets corner upright on level sites.

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	Swivel Short Tee
7.			A versatile fitting, usually in pairs. Although the photo shows two fittings, this item is sold and priced individually. The through tube (vertical in photo) cannot be joined within the fitting. Note: Image shows 2 fittings.

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	Centre Cross.
8.			Designed to form a 90° joint between an upright which passes through the fitting and four other tubes. Usually used in the middle of larger structures such as self-contained play area. The through tube (vertical in photo) cannot be joined within the fitting.

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	Single Swivel Connection.
9.			A versatile swivel fitting, useful for awkward applications where angles cannot be accommodated by adjustable angle fittings. The through tube (sloping in photo) cannot be joined within the fitting.

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	Side Outlet Tee.
10.		Often used in large tubular structures with the upright passing through the fitting. The through tube (vertical in photo) cannot be joined within the fitting.

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Setscrew.

Please Note: All fittings are supplied with setscrews fitted as standard.

To look at purchasing this item click this button.

Hexagon Keys.

High quality imperial size hexagon keys.

Size: 5/16"

Note: You can purchase a security alan key along with a security set screw.

To look at purchasing this item click this button.

	Handrail/Tubing.
c.		Galvanised Medium Weight tube to BS EN 10255 (formerly BS1387). Ø : 42.4mm We sell 3 metre lengths of galvanised tubing, you can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

To look at purchasing this item click this button.

Case Study 10 - Shelving.

shelving

Here in this example we see the rails are arranged in a grid pattern. This gives a suitable sub frame for a shelving system.

The great thing about this example is that it only uses 3 different components, which are repeated throughout the structure.

	Railing Base Flange.
1			Base flange, usually used for uprights on level sites. Fixing holes suit a wide range of common mechanical and chemical masonry anchors which we should be pleased to quote for on request.

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	Combined Tee & Crossover
2.			Often used in racking and similar structures, the fitting allows both uprights and front and rear horizontal rails to be continuous. It is usually preferable for the upright to be on the outside of the structure (as per the photo) for maximum stability. The trough tubes cannot be joined within the fitting.

To look at purchasing this item click this button.

	Wall Flange.
3			Positional fixing flange which is often used where rails meet walls on level sites.

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Setscrew.

Please Note: All fittings are supplied with setscrews fitted as standard.

To look at purchasing this item click this button.

Hexagon Keys.

High quality imperial size hexagon keys.

Size: 5/16"

Note: You can purchase a security alan key along with a security set screw.

To look at purchasing this item click this button.

	Handrail/Tubing.
c.		Galvanized Medium Weight tube to BS EN 10255 (formerly BS1387). Ø : 42.4mm We sell 3 metre lengths of galvanised tubing, you can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

To look at purchasing this item click this button.

Case Study 11 - Covered Trolley Bay

covered trolley bay

This covered trolley bay was constructed using just a few repeating components.

The plastic panels (by others) including the roof are riveted into the rails for security.

	Short Tee.
1.			90° butt joint, often used to join intermediate uprights to top rails and middle rails to end uprights on levels. This clamp cannot be used where through tube (horizontal in photo) has to be joined within the fitting.

To look at purchasing this item click this button.

	Cross (Middle Rail).
2.			90° joint, often used between middle rail and uprights on level sites. The through tube (vertical in photo) cannot be joined within the fitting.

To look at purchasing this item click this button.

	90° Elbow.
3.			90° angle joint, often used where top rail meets end upright on level sites.

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	Wall Flange.
4.			Positional fixing flange which is often used where rails meet walls on level sites.

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	Crossover.
5.			Designed to form 90° crossover joint between two tubes, this fitting can reduce the need for cutting on the horizontal rails.

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	Side Outlet Tee.
6.		Often used in large tubular structures with the upright passing through the fitting. The through tube (vertical in photo) cannot be joined within the fitting.

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Setscrew.

Please Note: All fittings are supplied with setscrews fitted as standard.

To look at purchasing this item click this button.

Hexagon Keys.

High quality imperial size hexagon keys.

Size: 5/16"

Note: You can purchase a security alan key along with a security set screw.

To look at purchasing this item click this button.

	Handrail/Tubing.
c.		Galvanised Medium Weight tube to BS EN 10255 (formerly BS1387). Ø : 42.4mm We sell 3 metre lengths of galvanised tubing, you can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

To look at purchasing this item click this button.

Case Study 12 - Clothes Stand.

clothes stand

This simple structure allows a retailer to display their clothing products. The critical component is the wall bracket, which in this instance has been used to support the horizontal rail used to hang the clothes.

	Handrail Wall Bracket
1.			Often used to attach to walls as a position wall fixing for structures, or to attach kick plates to uprights. the tube cannot be joined within the fitting.

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	Corner (Middle Rail).
2.			90° corner joint, often used on middle rail on level sites. The through tube (vertical in photo) cannot be joined within the fitting.

To look at purchasing this item click this button.

Setscrew.

Please Note: All fittings are supplied with setscrews fitted as standard.

To look at purchasing this item click this button.

Hexagon Keys.

High quality imperial size hexagon keys.

Size: 5/16"

Note: You can purchase a security alan key along with a security set screw.

To look at purchasing this item click this button.

	Handrail/Tubing.
c.		Galvanised Medium Weight tube to BS EN 10255 (formerly BS1387). Ø : 42.4mm We sell 3 metre lengths of galvanised tubing, you can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

To look at purchasing this item click this button.

Case Study 13 - Steps With Barrier.

These concrete steps have been finished with a safety barrier design.

A number of different components have been used including the double swivel combination (5) to allow the rails to be placed at sloping angles.

	90° Elbow.
1.			90° angle joint, often used where top rail meets end upright on level sites.

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	Adjustable Short Tee.
2.			90° angle joint, often used where top rail meets end upright on level sites.

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	Short Tee.
3.			90° butt joint, often used to join intermediate uprights to top rails and middle rails to end uprights on levels. This clamp cannot be used where through tube (horizontal in photo) has to be joined within the fitting.

To look at purchasing this item click this button.

	Railing Base Flange.
4.			Base flange, usually used for uprights on level sites. Fixing holes suit a wide range of common mechanical and chemical masonry anchors which we should be pleased to quote for on request.

To look at purchasing this item click this button.

	90° Corner Double Swivel Combination.
5.			A versatile swivel fitting, useful for awkward applications where angles cannot be accommodated by adjustable angle fittings. The through tube (vertical in photo) cannot be joined within the fitting. The assembly is riveted together.

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	Variable Elbow (15° - 60°).
6.			Variable 15° to 60° angle joint, often used to join staircase top rail to end uprights.

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Setscrew.

Please Note: All fittings are supplied with setscrews fitted as standard.

To look at purchasing this item click this button.

Hexagon Keys.

High quality imperial size hexagon keys.

Size: 5/16"

Note: You can purchase a security alan key along with a security set screw.

To look at purchasing this item click this button.

	Handrail/Tubing.
c.		Galvanised Medium Weight tube to BS EN 10255 (formerly BS1387). Ø : 42.4mm We sell 3 metre lengths of galvanised tubing, you can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

To look at purchasing this item click this button.

Case Study 14 - Marine Barge Platform.

marine barge and platform

The design of this marine platform means that no welding is needed to construct the barriers so the design can be changed easily.

Angled fittings are used for the stairway and a hinged gate has been made for elevated access to the top platform.

	Side Palm.
1.			A palm-type fitting, often used to attach guardrail uprights to walls, staircases and ramps. In standard form, the tube cannot pass through the bottom of the fitting, although the fitting may be modified to accommodate this at extra cost (with loss of use of bottom bolt hole).

To look at purchasing this item click this button.

	Adjustable Cross (Middle Rail)
2.			90° corner joint, often used where top rail meets corner upright on level sites.

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	Single Swivel Combination Male Part.
3.			Single lugged fitting. Dependent on load requirements, this fitting may sometimes be used to fix flat sheets to tubes. The tube cannot be joined within the fitting.

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	Adjustable Short Tee.
4.			Adjustable from30° to 60° often used on staircase top rails and braces. The through tube (sloping in photo) cannot be joined within the fitting.

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	90° Elbow.
5.			90° angle joint, often used where top rail meets end upright on level sites.

To look at purchasing this item click this button.

	Long Tee.
6.			90° joint, often used to join intermediate uprights to top rails on level sites.

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	Railing Base Flange.
7.			Base flange, usually used for uprights on level sites. Fixing holes suit a wide range of common mechanical and chemical masonry anchors which we should be pleased to quote for on request.

To look at purchasing this item click this button.

	Cross (Middle Rail).
8.			90° joint, often used between middle rail and uprights on level sites. The through tube (vertical in photo) cannot be joined within the fitting.

To look at purchasing this item click this button.

	Short Tee.
9.			90° butt joint, often used to join intermediate uprights to top rails and middle rails to end uprights on levels. This clamp cannot be used where through tube (horizontal in photo) has to be joined within the fitting.

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	Gate Hinge Pin.
10.			Often used with gate eye to form gate hinges. The tube cannot be joined within the fitting.

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Gate Eye.

11.

Often used with gate eye hinge pin to form gate hinges. The tube cannot be joined within the fitting.

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Setscrew.

a.
Please Note: All fittings are supplied with setscrews fitted as standard.
High quality setscrews, a vital component in the high structural integrity of the fittings.

Thread : 3/8"
Alan Key Size : 5/16"

N.B. All fittings are supplied with setscrews fitted as standard. But you can purchase additional setscrews if required. Also note you can purchase a security set screw in our online shop also, along with security fix hex key.

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Hexagon Keys.

High quality imperial size hexagon keys.

Size: 5/16"

Note: You can purchase a security alan key along with a security set screw.

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	Handrail/Tubing.
c.		Galvanised Medium Weight tube to BS EN 10255 (formerly BS1387). Ø : 42.4mm We sell 3 metre lengths of galvanised tubing, you can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

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Case Study 15 - Banners.

banners

This banner frame was created using just 4 repeating connection types.

	Short Tee.
1.			90° butt joint, often used to join intermediate uprights to top rails and middle rails to end uprights on levels.

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	90° Elbow.
2.			90° angle joint, often used where top rail meets end upright on level sites.

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	Long Tee.
3.			90° joint, often used to join intermediate uprights to top rails on level sites.

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	Railing Base Flange.
4.			Base flange, usually used for uprights on level sites. Fixing holes suit a wide range of common mechanical and chemical masonry anchors which we should be pleased to quote for on request.

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Setscrew.

Please Note: All fittings are supplied with setscrews fitted as standard.

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Hexagon Keys.

High quality imperial size hexagon keys.

Size: 5/16"

Note: You can purchase a security alan key along with a security set screw.

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	Handrail/Tubing.
c.		Galvanised Medium Weight tube to BS EN 10255 (formerly BS1387). Ø : 42.4mm We sell 3 metre lengths of galvanised tubing, you can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

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Building Your Handrail System.

Our handrail system is ingenious and easy to install.

All our parts need NO welding.

It takes just a few hours on site to create an impressive handrail design.

As well as being in standard galvanised form, we can also powder coat your handrails and fittings in the following standardised colours:

Yellow - RAL1018 (Necessary for DDA Regulations)
Red - RAL3020
Blue - RAL5002
Green - RAL6018
Black - RAL9005
White - RAL9016

Examples of handrail fittings:

Here are a few examples of how some of the handrail connectors are fitted to the handrails.

1. Short Tee

The short tee is used to join a *single* horizontal top rail to a *single* vertical lower rail. The horizontal rail passes straight through the connector. Only the set screws are tightened using the supplied hexagon key.

2. Long Tee

The long Tee connector is used to attach *two* horizontal rails to one vertical rail. The two horizontal rails meet in the top part of the connector and the vertical rail sits in the bottom of the connector. When the rails are seated they are secured with the setscrews.

3. 90° Elbow.

The 90° elbow provides a perpendicular fit to a single vertical and *single* horizontal rail. The rails fit into the connector as shown and are secured by the two seperate setscrews which are tightened by the hex key.

4. Base Flange Support.

The base flange support firstly needs to be anchored using M12 anchor bolts. The handrail is then put in and secured using the setscrews tightened with the hex key.

5. Side Support (Vertical).

For wall mounted handrail systems, the vertical base side support can be used. The support is firstly anchored into the wall using a M12 anchor bolt. The handrail is then placed in and secured using the setscrews.

6. Corner (Top Rail).

The corner (top rail) connector is used to connect *two* perpendicular horizontal rails with *one* vertical rail. The rails slide into the connector as shown and are secured using the supplied setscrews.

7. Gate System.

To construct a gate-hinge system, the gate pin is secured to one of the vertical handrails (this is part of the gate itself) using the setscrew. The handrail acts as one side of the gate. The gate eye is then secure the other vertical handrail is then threaded over the gate pin and secured to the other rail. It is recommended that at least one other hinge is made before a working gate system can be safely forged.

8. Double Hinged Swivel.

Two female swivel parts (horizontal) are attached via rivets to a vertical double male adaptor. This allows the two horizontal rails to move through approximately 90°.

9. Crossover.

The crossover component allows a *single* vertical and *single* horizontal handrail to be joined together perpendicularly. Both handrails slide all the way through the crossover sections and are secured in place by two setscrews.

10. Combined Tee & Crossover.

The crossover tee component combines *two* horizontal rails and *one* vertical rail. One of the horizontal rails are terminated in the tee and the other is allowed (like the vertical rail) to slide all the way through. All rails are secured by three sperate setscrews.

DDA (Disabled Discrimination Act) Assist Installation.

1. Planning:

The maximum separation of upright posts is dependant on design loads and posts should be spaced evenly for aesthetic reasons where possible.

It is recommended that posts that need to be positioned on a corner are given a maximum distance of 300mm from that corner.

dda assist installation - planning

Before starting to assemble the structure, check to make sure you have received all nessecary lengths of tubes and fittings.

2. Prepare the posts:
Pre-assemble upright posts with required fittings. For variations in the terrain, it is recommended that the posts are cut and grounded in such a way to allow for this unevenness in the ground. This avoids any unsightly bends or kinks in the structure. Mid rail heights can be adjusted easily using the mid rail clamp.

3. Mark out positions of posts:
On site,mark out the positions of the posts taking care to ensure an even distance between posts, without exceeeding regulations and also making sure the posts run in a straight line where needed.

4. Assembling the railing system:
Starting with the post nearest a fixed structure (e.g. a wall), position this first post and assemble the top and mid rails in place. Support the top and mid rails by hand before fitting the next upright post as follows.

It is recommended to use our assist rubber o-ring between fittings and tube to allow a much better and more visually pleasing finish.

assembling the railing system

assembly railing system

To improve safety and aesthetics, all tubing must be deburred and treated with suitable zinc-rich protection.

To ensure rigidity and safety, all base fittings should be aligned perpendiclar to the direction of the handrail.

assembling the railing system

For assembling the rest of the structure. it may be necessary to loosen the setscrews on the already constructed fittings and tubing. This will allow easier positioning and fitting of the rest of the tubing.

5. Basic Final Checks.

For final inspection, check that all the setscrews are tightened and there are no sharp corners on the handrails.

Cutting Handrails.

There are three main methods of cutting the handrails down to the required sizes:

chop saw

angle grinder

hacksaw

1. Using a Chop Saw

Things you'll need: Working saw with proper blade Safety equipment (face, eye, respirator)
How to use a Steel Chop Saw.
1.	Familiarize yourself with the saw. A steel chop saw is used to cut pieces of steel and other hard materials. Different than common saws that cut wood, chop saws use abrasive disks (blades) to make cuts. When operated properly, a chop saw makes very precise cuts through steel.
2.	Install a proper blade. All chop saws essentially use the same type of blade. The most common and the most reliable blades are 355mm in diameter and have a 3mm centre hole. The blade should be 3mm thick. It is important to follow the warnings and installation instructions printed on your blade. Installing a blade properly is crucial, improperly installed blades will cause the saw to mis-function and could result in serious injury. The blade of a chop saw will wear and get progressively smaller with use. Always replace blades that are too small to continue cutting.
3.	Safely position your saw. Cutting steel will likely involve sparks, soot and dust from your saw. To protect the surface on which your saw will be placed such as a work bench, counter top or floor, place a piece of sheet metal or wet sheet of plywood under the saw itself. Makes sure it is level. If you are close to walls, windows or curtains, it is wise to cover those things to prevent damaging them while you work.
4.	Position the steel properly. It is important to allow the blade of the saw to work freely, it is therefore, necessary to place the piece of steel in a position that will allow the saw to perform top-to-bottom cuts, this is accomplished by resting flat pieces of steel on end to avoid flat cuts.
5.	Begin cutting. Setting up the chop saw for an optimum cut will first require you to properly line up the blade with the piece of steel, this can be done by using a pencil, thin tipped marker and a metal rule or square. Once you have properly lined up the cut, hold the material with your left hand to ensure it stays against the fence of the saw. With your right hand, grab the saw's arm and press the trigger. Slowly push the arm to the material. Do not push too hard, again let the saw do the work. If you see an abormal amount of dust and sparks, you are likely pushing too hard on the arm and must ease up, pressing too hard will damage your blade and possibly ruin the saw's engine, which may result in a poor cut. When the steel has been cut, raise the arm and release the trigger.

1. Using an Angle Grinder

Things you'll need: Tape measure Scratch awl Straightedge .040 cutoff wheels Angle grinder 40 grit flapper wheel
How to use an Angle Grinder.
1.	Pull a tape measure along a piece of steel. Mark the cut location in two spots on the steel with a scratch awl.
2.	Align a straightedge with the two marks, drag a scratch awl along the straighedge to connect the two length marks. Remove the straightedge from the surface of the steel.
3.	*Secure* a .040 cutoff wheel to an angle grinder. Start the grinder. Align the spinning cutoff wheel with the marked line.
4.	Score along the line with the spinning cutoff wheel. Replace the cutoff wheel when it wears down to the printed section on the front side of the blade. Work back and forth along the entire line until you cut the steel to length.
5.	Exchange the .040 cutoff wheel for a 40-grit flapper wheel.
6.	Run the flapper wheel along both sides of the cut edge to remove the sharp burr remaining on the metal. Allow the steel to cool for one hour *before handling.*

3. Using a Hacksaw

How to use a Hacksaw.
1.	Measure the steel pipe length required.
2.	Mark the spot requiring cutting using a scriber.
3.	Clamp the steel pipe on the vice firmly with the portion to be cut extending from the vice jaws.
4.	Inspect the hacksaw to ensure the blade is properly fastened.
5.	Grip the hacksaw by the handle and place the blade tooth on the earlier marked spot.
6.	Move the saw back and forth applying pressure with the left hand as the saw cuts.
7.	Cut steadily and slowly across the pipe cross section.
8.	Slacken the vice grip and remove the cut piece of the steel pipe.

Pear Stairs sell a number of products to finish your staircase. Remember if you have any questions don't hesitate to phone us about your staircase finish. We are a friendly company, phone Pear Stairs on 01938 553311.

The Stairs and Staircase Company

Barrier and Handrail System.

Building Your Handrail System.

Building Your Handrail System.

DDA (Disabled Discrimination Act) Assist Installation.

Cutting Handrails.