Barrier and Handrail System

Pear Stairs are able to offer barrier and handrail systems for any gates, steps, stairways, shelving or safety barriers. We have a wide range of barrier and handrails available. Below are the different types that we can supply.

Building Your Handrail System

All fittings are compatible with our standard 42mm galvanised tubing. For any other sizes, please phone Pear Stairs on 01938 553311.

We have sold systems for many purposes and situations. These include:

  1. Safety barriers

  2. Gates

  3. Shelving

  4. Stairway handrails

There are many more examples. Below are some of our case studies, to help you choose the correct fittings for any circumstances.

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 falls from the elevated platform. It was secured using both base flange (item 7) and vertical side supports (item 8).

1

Short Tee

   
  short tee (base and wall fixings)

short tee sketch (base and wall fixings)

90° butt joint, often used to join intermediate uprights to top rails, and middle rails to end uprights on level sites.

Short Tee

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2

Cross (middle rail)

   
 

cross (middle rail) - (base and wall fixings)

cross (middle rail) (wall and base fixings)

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

Cross (middle rail)

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3

Corner (top rail)

   
  corner (top rail) - (base and wall fixings)

corner (top rail) - (base and wall fixings)

90° corner joint, often used where the top rail meets a corner upright on level sites.

Corner (top rail)

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4

Corner (middle rail)

   
  corner (top rail) - base and wall fixings)

corner (middle rail) - (wall and base fixings)

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

Corner (middle rail)

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5

90° Elbow

   
  90° elbow (wall and floor fixings)

90° elbow (wall and floor fixings)

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

Elbow (90 degree)

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6

Long Tee

   
  long tee (wall and base fittings)

long tee sketch (wall and base fixings)

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

Long tee

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7

Railing Base Flange

   
  railing base flange (wall and floor fixings)

railing base flange sketch (wall and floor fixings)

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

Rail Base Flange

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8

Side Support (vertical base)

 
  side support (vertical base)- (wall and floor fittings)

side support (vertical base) (wall and floor fittings)

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

Side Support (vertical base)

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a

Setscrew

   
  setscrew (wall and floor fixing)

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", allen key size: 5/16". We supply all fittings with setscrews fitted as standard, but you can purchase additional setscrews if required. You can also buy a security setscrew in our online shop, along with a security fix hex key.

Set screw

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b

Hexagon keys

   
  hexagon keys

High quality imperial size hexagon keys. Size: 5/16". Please Note: You can purchase a security allen key along with a security setscrew.

Hexagon keys

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c

Handrail/Tubing

 
  tubing

Galvanised medium weight tube to BS EN 10255 (formerly BS1387). Size: 42.4mm. We sell galvanised tubing in 3m lengths. You can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

Handrail / Tubing

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Case Study 2 - Gate System and Wire Mesh Panels

gate system and wire mesh panels

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

1

Mesh Panel

   
  mesh panel (gate system and wire mesh panels)

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

 

 

2

Single Mesh Panel Clip

 
  single mesh panel clip (gate system and wire mesh panels)

single mesh panel clip (gtes sytem and wire mesh panels)

For attaching mesh panels to one side of tube. Please Note: This item is manufactured from steel, not malleable iron. Designed to suit 8mm rod.

Single mesh panel clip

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3

Gate Hinge Pin

 
  gate hinge pin (gate system and wire mesh panels)

gate hinge pin (gate system and wire mesh panels)

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

Gate hinge pin

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4

Gate Eye

 

 

 
gate eye (gate system and wire mesh panels)

gate eye (gate system and wire mesh panels)

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

Gate eye

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a

Setscrew

   
  setscrew (wall and floor fixing)

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", allen key size: 5/16". We supply all fittings with setscrews fitted as standard, but you can purchase additional setscrews if required. You can also buy a security setscrew in our online shop, along with a security fix hex key.

Set screw

 Shop for this item

 

b

Hexagon Keys

   
  hexagon keys

High quality imperial size hexagon keys. Size: 5/16". Please Note: You can purchase a security allen key along with a security setscrew.

Hexagon keys

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c

Handrail/Tubing

 
  tubing

Galvanised medium weight tube to BS EN 10255 (formerly BS1387). Size: 42.4mm. We sell galvanised tubing in 3m lengths. You can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

Handrail / Tubing

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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 components. These parts can be combined to forge a handrail system as shown in the pedestrian guardrail pictured above.

1

Short Tee

   
  short tee (base and wall fixings)

short tee sketch (base and wall fixings)

90° butt joint, often used to join intermediate uprights to top rails, and middle rails to end uprights on level sites.

Short tee

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2

Long Tee

   
  long tee (wall and base fittings)

long tee sketch (wall and base fixings)

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

Long tee

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3

Cross (middle rail)

   
.

cross (middle rail) - (base and wall fixings)

cross (middle rail) (wall and base fixings)

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

Cross (middle rail)

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4

90° Elbow

   
  90° elbow (wall and floor fixings)

90° elbow (wall and floor fixings)

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

Elbow (90 degree)

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5

Railing Base Flange

   
  railing base flange (wall and floor fixings)

railing base flange sketch (wall and floor fixings)

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

Rail base flange

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a

Setscrew

   
  setscrew (wall and floor fixing)

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", allen key size: 5/16". We supply all fittings with setscrews fitted as standard, but you can purchase additional setscrews if required. You can also buy a security setscrew in our online shop, along with a security fix hex key.

Set screw

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b

Hexagon Keys

   
  hexagon keys

High quality imperial size hexagon keys. Size: 5/16". Please Note: You can purchase a security allen key along with a security setscrew.

Hexagon keys

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c

Handrail/Tubing

 
  tubing

Galvanised medium weight tube to BS EN 10255 (formerly BS1387). Size: 42.4mm We sell galvanised tubing in 3m lengths. You can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

Handrail / Tubing

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Case Study 4 - Stairway

stairway

This installation shows one of our barrier and handrails system used on a two-tier stairway. This simple system uses several different parts which interconnect, creating a safe environment to ensure the easy flow of several thousand people. The vertical posts have simply been concreted into the ground, with no ground mountings needed.

1

Short Tee

   
  short tee (base and wall fixings)

short tee sketch (base and wall fixings)

90° butt joint, often used to join intermediate uprights to top rails, and middle rails to end uprights on level sites.

This clamp cannot be used where the through tube (horizontal in photo) has to be joined within the fitting.

Short tee

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2

Cross (middle rail)

   
 

cross (middle rail) - (base and wall fixings)

cross (middle rail) (wall and base fixings)

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

Cross (middle rail)

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3

Variable Elbow (15° - 60°)

 
 

variable elbow

variable elbow

Variable 15° to 60° angle joint, often used to join the staircase top rail to end uprights.

Variable elbow (15-60 degrees)

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4

90° Elbow

   
  90° elbow (wall and floor fixings)

90° elbow (wall and floor fixings)

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

Elbow (90 degrees)

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5

Double Swivel Connection

 
  double swivel connection

double swivel connection

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

Double swivel connection

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6

Single Swivel Connection

 
  single swivel combination

single swivel combination sketch

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.

Single swivel connection

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a

Setscrew

   
  setscrew (wall and floor fixing)

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", allen key size: 5/16". We supply all fittings with setscrews fitted as standard, but you can purchase additional setscrews if required. You can also buy a security setscrew in our online shop, along with a security fix hex key.

Set screw

Shop for this item 

b

Hexagon Keys

   
  hexagon keys

High quality imperial size hexagon keys. Size: 5/16". Please Note: You can purchase a security allen key along with a security setscrew.

Hexagon keys

Shop for this item

c

Handrail/Tubing

 
  tubing

Galvanised medium weight tube to BS EN 10255 (formerly BS1387). Size: 42.4mm. We sell galvanised tubing in 3m lengths. You can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

Handrail / Tubing

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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 makes use of nine different components to construct the guarded ramp system.

1

Short Tee

   
  short tee (base and wall fixings)

short tee sketch (base and wall fixings)

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

Short tee

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2

90° Elbow

   
  90° elbow (wall and floor fixings)

90° elbow (wall and floor fixings)

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

Elbow (90 degree)

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3

Plastic Stop End

   
  plastic stop end

The plastic stop end fits over the end of the tubing to keep out insects, water and dirt.

Plastic stop end

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4

Handrail Wall Bracket

   
  handrail wall bracket

handrail wall bracket sketch

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.

Handrail wall bracket

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5

Side Support (vertical base)

 
  side support (vertical base)

handrail wall bracket sketch

Frequently 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.

Side support (vertical base)

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6

Combined Tee and Crossover

 
  combined tee and crossover

combined tee and crossover

Often used in racking and similar structures, the fitting allows both uprights and front and rear horizontal rails to run continuously.

It is preferable for the upright to be on the outside of the structure (as in the photo) for maximum stability. The through tubes cannot be joined within the fitting.

Combined tee and crossover

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7

Double Swivel Connection

 
  double swivel connection

double swivel connection

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

Double swivel connection

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8

Single Swivel Connection

 
  single swivel combination

single swivel combination sketch

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.

Single swivel connection

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a

Setscrew

   
  setscrew (wall and floor fixing)

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", allen key size: 5/16". We supply all fittings with setscrews fitted as standard, but you can purchase additional setscrews if required. You can also buy a security setscrew in our online shop, along with a security fix hex key.

Set screw

Shop for this item 

b

Hexagon Keys

   
  hexagon keys

High quality imperial size hexagon keys. Size: 5/16". Please Note: You can purchase a security allen key along with a security setscrew.

Hexagon keys

Shop for this item

c

Handrail/Tubing

 
  tubing

Galvanised medium weight tube to BS EN 10255 (formerly BS1387). Size: 42.4mm We sell galvanised tubing in 3m lengths. You can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

Handrail / Tubing

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Case Study 6 - Disabled Ramp Access

disabled ramp access

The above example is a handrail system designed 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 all it takes to tighten the setscrews. Like all our systems, it requires no welding, threading or riveting, so no special equipment is needed. Further instructions on how to assemble a system to help disabled users can be found in our section 'Building Your Handrail System - DDA Assist Installation Guide'.

1

Short Tee

   
  short tee (base and wall fixings)

short tee sketch (base and wall fixings)

90° butt joint, often used to join intermediate uprights to top rails and middle rails to end uprights on level sites.

This clamp cannot be used where through tube (horizontal in photo) has to be joined within the fitting.

Short tee

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2

90° Elbow

   
  90° elbow (wall and floor fixings)

90° elbow (wall and floor fixings)

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

Elbow (90 degree)

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3

Railing Base Flange

   
  railing base flange (wall and floor fixings)

railing base flange sketch (wall and floor fixings)

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

Rail base flange

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4

Assist Elbow

   
  assist elbow

assist elbow sketch

90° elbow for joining together angled tubing.

Assist elbow

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5

Assist Internal Swivel Bracket

 
  assist internal swivel bracket

assist internal swivel bracket

To attach handrail to an upright at any angle when used in conjunction with 90° elbow.

Assist internal swivel bracket

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6

Assist O-Ring (optional)

 
  assist o-ring

An optional extra which can be fitted to each end of the expanding assist fittings, to attain the best finish.

Assist O ring

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7

Aluminium Stop End

 
  aluminium stop end

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

Aluminium stop end

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a

Setscrew

   
  setscrew (wall and floor fixing)

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", allen key size: 5/16". We supply all fittings with setscrews fitted as standard, but you can purchase additional setscrews if required. You can also buy a security setscrew in our online shop, along with a security fix hex key.

Set screw

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b

Hexagon Keys

   
. hexagon keys

High quality imperial size hexagon keys. Size: 5/16". Please Note: You can purchase a security allen key along with a security setscrew.

Hexagon keys

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c

Handrail/Tubing

 
  tubing

Galvanised medium weight tube to BS EN 10255 (formerly BS1387). Size: 42.4mm We sell galvanised tubing in 3m lengths. You can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

Railing / Tubing

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Case Study 7 - Wall Mountings

wall mountings

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

1

Wall Flange

   
  wall flange

wall flange

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

Wall flange

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2

Short Tee

   
  short tee (base and wall fixings)

short tee sketch (base and wall fixings)

90° butt joint, often used to join intermediate uprights to top rails, and middle rails to end uprights on level sites.

This clamp cannot be used where the through tube (horizontal in photo) has to be joined within the fitting.

Short tee

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3

90° Elbow

   
  90° elbow (wall and floor fixings)

90° elbow (wall and floor fixings)

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

Elbow (90 degree)

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4

Side Palm

   
  side palm

side palm

A palm-type fitting, frequently used to attach guardrail uprights to walls, staircases and ramps.

In its 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).

Side palm

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a

Setscrew

   
  setscrew (wall and floor fixing)

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", allen key size: 5/16". We supply all fittings with setscrews fitted as standard, but you can purchase additional setscrews if required. You can also buy a security setscrew in our online shop, along with a security fix hex key.

Set screw

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b

Hexagon Keys

   
  hexagon keys

High quality imperial size hexagon keys. Size: 5/16". Please Note: You can purchase a security allen key along with a security setscrew.

Hexagon keys

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c

Handrail/Tubing

 
  tubing

Galvanised medium weight tube to BS EN 10255 (formerly BS1387). Size: 42.4mm We sell galvanised tubing in 3m lengths. You can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

Railing / Tubing

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Case Study 8 - Pedestrian Barrier

pedestrian barrier

This is an example of a coastal pedestrian barrier and handrail, using our galvanised range of tubing. It was built to protect the public from falling into the sea. The pedestrian barrier panel (2) dimensions can be constructed based on individual customer requirements.

1

Long Tee

   
  long tee (wall and base fittings)

long tee sketch (wall and base fixings)

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

Long tee

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2

Pedestrian Barrier Panel

 
  pedestrian barrier panel

This provides rapid construction of pedestrian control structures using 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 for details.

 

3

Cross (middle rail)

   
 

cross (middle rail) - (base and wall fixings)

cross (middle rail) (wall and base fixings)

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

Cross (middle rail)

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4

Railing Base Flange

   
  railing base flange (wall and floor fixings)

railing base flange sketch (wall and floor fixings)

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

Rail base flange

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a

Setscrew

   
  setscrew (wall and floor fixing)

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", allen key size: 5/16". We supply all fittings with setscrews fitted as standard, but you can purchase additional setscrews if required.

You can also buy a security setscrew in our online shop, along with a security fix hex key.

Set screw

Shop for this item

b

Hexagon Keys

   
  hexagon keys

High quality imperial size hexagon keys. Size: 5/16". Please Note: You can purchase a security allen key along with a security setscrew.

Hexagon keys

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c

Handrail/Tubing

 
  tubing

Galvanised medium weight tube to BS EN 10255 (formerly BS1387). Size: 42.4mm We sell galvanised tubing in 3m lengths. You can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

Railing / Tubing

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Case Study 9 - Soft Play Area

softplay area

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

1

Short Tee

   
  short tee (base and wall fixings)

short tee sketch (base and wall fixings)

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.

Short tee

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2

Corner (middle rail)

   
  corner (top rail) - base and wall fixings)

corner (middle rail) - (wall and base fixings)

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

Corner (middle rail)

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3

Cross (middle rail)

   
 

cross (middle rail) - (base and wall fixings)

cross (middle rail) (wall and base fixings)

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

Cross (middle rail)

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4

90° Elbow

   
  90° elbow (wall and floor fixings)

90° elbow (wall and floor fixings)

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

Elbow (90 degree)

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5

Corner (top rail)

   
  corner (top rail) - (base and wall fixings)

corner (top rail) - (base and wall fixings)

90° corner joint, frequently used where the top rail meets a corner upright on level sites.

Corner (top rail)

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6

Adjustable Cross (middle rail)

 
  adjustable cross (middle rail)

adjustable cross (middle rail)

90° corner joint, often employed where the top rail meets a corner upright on level sites.

Adjustable cross (middle rail)

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7

Swivel Short Tee

 
  swivel short tee

swivel short tee

A versatile fitting, normally used 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.

Swivel short tee

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8

Centre Cross

 
  centre cross

centre cross

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 areas. The through tube (vertical in photo) cannot be joined within the fitting.

Centre cross

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9

Single Swivel Connection

 
  single swivel combination

single swivel combination sketch

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.

Single swivel connection

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10

Side Outlet Tee

   
  side outlet tee

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.

Side outlet tee

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a

Setscrew

   
  setscrew (wall and floor fixing)

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", allen key size: 5/16". We supply all fittings with setscrews fitted as standard, but you can purchase additional setscrews if required. You can also buy a security setscrew in our online shop, along with a security fix hex key.

Set screw

Shop for this item

b

Hexagon Keys

   
  hexagon keys

High quality imperial size hexagon keys. Size: 5/16". Please  Note: You can purchase a security allen key along with a security setscrew.

Hexagon keys

Shop for this item

c

Handrail/Tubing

 
  tubing

Galvanised medium weight tube to BS EN 10255 (formerly BS1387). Size: 42.4mm We sell galvanised tubing in 3m lengths. You can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

Railing / Tubing

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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.

1

Railing Base Flange

   
  railing base flange (wall and floor fixings)

railing base flange sketch (wall and floor fixings)

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

Rail base flange

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2

Combined Tee and Crossover

 
. combined tee and crossover

combined tee and crossover

Often used in racking and similar structures, the fitting allows both uprights and front and rear horizontal rails to run continuously.

It is usually preferable for the upright to be on the outside of the structure (as in the photo) for maximum stability. The through tubes cannot be joined within the fitting.

Combined tee and crossover

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3

Wall Flange

   
  wall flange

wall flange

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

Wall flange

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a

Setscrew

   
  setscrew (wall and floor fixing)

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", allen key size: 5/16". We supply all fittings with setscrews fitted as standard, but you can purchase additional setscrews if required. You can also buy a security setscrew in our online shop, along with a security fix hex key.

Set screw

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b

Hexagon Keys

   
  hexagon keys

High quality imperial size hexagon keys. Size: 5/16". Please Note: You can purchase a security allen key along with a security setscrew.

Hexagon keys

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c

Handrail/Tubing

 
  tubing

Galvanized medium weight tube to BS EN 10255 (formerly BS1387). Size: 42.4mm We sell galvanised tubing in 3m lengths. You can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

Railing / Tubing

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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.

1

Short Tee

   
  short tee (base and wall fixings)

short tee sketch (base and wall fixings)

90° butt joint, often used to join intermediate uprights to top rails, and middle rails to end uprights on level sites.

This clamp cannot be used where through tube (horizontal in photo) has to be joined within the fitting.

Short tee

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2

Cross (middle rail)

   
 

cross (middle rail) - (base and wall fixings)

cross (middle rail) (wall and base fixings)

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

Cross (middle rail)

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3

90° Elbow

   
  90° elbow (wall and floor fixings)

90° elbow (wall and floor fixings)

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

Elbow (90 degree)

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4

Wall Flange

   
  wall flange

wall flange

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

Wall flange

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5

Crossover

   
  crossover

crossover

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

Crossover

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Side Outlet Tee

   
  side outlet tee

Frequently used in large tubular structures with the upright passing through the fitting. The through tube (vertical in photo) cannot be joined within the fitting.

Side outlet tee

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a

Setscrew

   
  setscrew (wall and floor fixing)

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", allen key size: 5/16". We supply all fittings with setscrews fitted as standard, but you can purchase additional setscrews if required. You can also buy a security setscrew in our online shop, along with a security fix hex key.

Set screw

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b

Hexagon Keys

   
  hexagon keys

High quality imperial size hexagon keys. Size: 5/16". Please Note: You can purchase a security allen key along with a security setscrew.

Hexagon keys

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c

Handrail/Tubing

 
  tubing

Galvanised medium weight tube to BS EN 10255 (formerly BS1387). Size: 42.4mm We sell galvanised tubing in 3m lengths. You can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

Railing / Tubing

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Case Study 12 - Clothes Stand

clothes stand

This simple structure allows a retailer to display 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.

1

Handrail Wall Bracket

   
  handrail wall bracket

handrail wall bracket sketch

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.

Handrail wall bracket

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2

Corner (middle rail)

   
  corner (top rail) - base and wall fixings)

corner (middle rail) - (wall and base fixings)

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

Corner (middle rail)

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a

Setscrew

   
  setscrew (wall and floor fixing)

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", allen key size: 5/16". We supply all fittings with setscrews fitted as standard, but you can purchase additional setscrews if required. You can also buy a security setscrew in our online shop, along with a security fix hex key.

Set screw

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b

Hexagon Keys

   
  hexagon keys

High quality imperial size hexagon keys. Size: 5/16". Please Note: You can purchase a security allen key along with a security setscrew.

Hexagon keys

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c

Handrail/Tubing

 
  tubing

Galvanised medium weight tube to BS EN 10255 (formerly BS1387). Size: 42.4mm We sell galvanised tubing in 3m lengths. You can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

Railing / Tubing

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Case Study 13 - Steps With Barrier

steps with barrier

These concrete steps have been finished with a safety barrier and handrail system. A number of different components have been used including the double swivel combination (5) to allow the rails to be placed at sloping angles.

1

90° Elbow

   
  90° elbow (wall and floor fixings)

90° elbow (wall and floor fixings)

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

Elbow (90 degree)

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Adjustable Short Tee

   
  adjustable short tee

adjustable short tee

90° angle joint, frequently used wherethe top rail meets an end upright on level sites.

Adjustable short tee

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3

Short Tee

   
  short tee (base and wall fixings)

short tee sketch (base and wall fixings)

90° butt joint, often employed to join intermediate uprights to top rails, and middle rails to end uprights on level sites.

This clamp cannot be used where the through tube (horizontal in photo) has to be joined within the fitting.

Short tee

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4

Railing Base Flange

   
  railing base flange (wall and floor fixings)

railing base flange sketch (wall and floor fixings)

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

Rail base flange

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5

90° Corner Double Swivel Combination

 
  90 corner double swivel combination

90 corner double swivel combination

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.

Corner double swivel combination (90 degrees)

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6

Variable Elbow(15° - 60°)

 
 

variable elbow

variable elbow

Variable 15° to 60° angle joint, often used to join staircase top rail to end uprights.

Variable elbow (15-60 degrees)

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a

Setscrew

   
  setscrew (wall and floor fixing)

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", allen key size: 5/16". We supply all fittings with setscrews fitted as standard, but you can purchase additional setscrews if required. You can also buy a security setscrew in our online shop, along with a security fix hex key.

Set screw

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b

Hexagon Keys

   
  hexagon keys

High quality imperial size hexagon keys. Size: 5/16". Please Note: You can purchase a security allen key along with a security setscrew.

Hexagon keys

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c

Handrail/Tubing

 
  tubing

Galvanised medium weight tube to BS EN 10255 (formerly BS1387). Size: 42.4mm We sell galvanised tubing in 3m lengths. You can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

Railing / Tubing

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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 configuration 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.

1

Side Palm

   
  side palm

side palm

A palm-type fitting, often used to attach guardrail uprights to walls, staircases and ramps.

In its 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).

Side palm

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2

Adjustable Cross (middle rail)

 
  adjustable cross (middle rail)

adjustable cross (middle rail)

90° corner joint, frequently employed where the top rail meets a corner upright on level sites.

Adjustable cross (middle rail)

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3

Single Swivel Combination Male Part

 
  single swivel combination male part

single swivel combintion male part

Single lugged fitting. Dependent on load requirements, it may sometimes be used to attach flat sheets to tubes. The tube cannot be joined within the fitting.

Single swivel combination male part

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4

Adjustable Short Tee

 
  adjustable short tee

adjustable short tee

Adjustable from 30° to 60°, this short tee is often used on staircase top rails and braces. The through tube (sloping in photo) cannot be joined within the fitting.

Adjustable short tee

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5

90° Elbow

   
  90° elbow (wall and floor fixings)

90° elbow (wall and floor fixings)

90° angle joint, frequently used where the top rail meets an end upright on level sites.

Elbow (90 degree)

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6

Long Tee

   
  long tee (wall and base fittings)

long tee sketch (wall and base fixings)

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

Long tee

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7

Railing Base Flange

   
  railing base flange (wall and floor fixings)

railing base flange sketch (wall and floor fixings)

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

Rail base flange

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8

Cross (middle rail)

   
 

cross (middle rail) - (base and wall fixings)

cross (middle rail) (wall and base fixings)

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

Cross (middle rail)

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9

Short Tee

   
  short tee (base and wall fixings)

short tee sketch (base and wall fixings)

90° butt joint, frequently used to join intermediate uprights to top rails, and middle rails to end uprights on level sites.

This clamp cannot be used where through tube (horizontal in photo) has to be joined within the fitting.

Short tee

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10

Gate Hinge Pin

 
  gate hinge pin (gate system and wire mesh panels)

gate hinge pin (gate system and wire mesh panels)

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

Gate hinge pin

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11

Gate Eye

 
  gate eye (gate system and wire mesh panels)

gate eye (gate system and wire mesh panels)

Frequently employed with a gate eye hinge pin to form gate hinges. The tube cannot be joined within the fitting.

Gate eye

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a

Setscrew

   
  setscrew (wall and floor fixing)

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", allen key size: 5/16". We supply all fittings with setscrews fitted as standard, but you can purchase additional setscrews if required. You can also buy a security setscrew in our online shop, along with a security fix hex key.

Set screw

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b

Hexagon Keys

   
  hexagon keys

High quality imperial size hexagon keys. Size: 5/16". Please Note: You can purchase a security allen key along with a security setscrew.

Hexagon keys

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c

Handrail/Tubing

 
  tubing

Galvanised medium weight tube to BS EN 10255 (formerly BS1387). Size: 42.4mm We sell galvanised tubing in 3m lengths. You can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

Railing / Tubing

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Case Study 15 - Banners

banners

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

1

Short Tee

   
  short tee (base and wall fixings)

short tee sketch (base and wall fixings)

90° butt joint, often used to join intermediate uprights to top rails, and middle rails to end uprights on level sites.

Short tee

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2

90° Elbow

   
  90° elbow (wall and floor fixings)

90° elbow (wall and floor fixings)

90° angle joint, frequently used where the top rail meets an end upright on level sites.

Elbow (90 degree)

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3

Long Tee

   
  long tee (wall and base fittings)

long tee sketch (wall and base fixings)

90° joint, frequently employed to join intermediate uprights to top rails on level sites.

Long tee

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4

Railing Base Flange

   
  railing base flange (wall and floor fixings)

railing base flange sketch (wall and floor fixings)

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.

Rail base flange

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a

Setscrew

   
  setscrew (wall and floor fixing)

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", allen key size: 5/16". We supply all fittings with setscrews fitted as standard, but you can purchase additional setscrews if required. You can also buy a security setscrew in our online shop, along with a security fix hex key.

Set screw

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b

Hexagon Keys

   
  hexagon keys

High quality imperial size hexagon keys. Size: 5/16". Please Note: You can purchase a security allen key along with a security setscrew.

Hexagon keys

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c

Handrail/Tubing

 
. tubing

Galvanised medium weight tube to BS EN 10255 (formerly BS1387). Size: 42.4mm We sell galvanised tubing in 3m lengths. You can purchase handrails pre-coated in six other colours, but they come in 2.8 lengths.

Railing / Tubing

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Building Your Handrail System

Our handrail system is ingenious and easy to install. NONE of our parts need welding. It takes just a few hours on site to create an impressive handrail design. As well as supplying 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; and White - RAL9016.

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

1 Short Tee

short tee sketch

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 setscrews are tightened using the supplied hexagon key.

2  Long Tee

long tee sketch

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

90° elbow sketch

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 separate setscrews which are tightened by the hex key.

4  Base Flange Support

base flange support sketch

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)

side support vertical sketch

side support vertical

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

6  Corner (top rail)

corner top rail sketch

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

gate system sketch

gate system

To construct a gate-hinge system, the gate pin is secured to one of the vertical handrails (part of the gate itself) using the setscrew. The handrail acts as one side of the gate. 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

double hinged swivel sketch

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

crossover sketch

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 and Crossover

combined tee and crossover sketch

combined tee and crossover

The crossover tee component combines two horizontal rails and one vertical rail. One of the horizontal rails is 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 separate setscrews.

DDA (Disabled Discrimination Act) Assist Installation

1  Planning

The maximum separation of upright posts is dependent 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 necessary lengths of tubes and fittings.

2  Prepare the posts

Pre-assemble upright posts with required fittings. Where there are variations in the terrain, it is recommended that the posts are cut and grounded accordingly 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.

prepare posts  - incorrect

dda assist installation - correct

3  Mark out positions of posts

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

dda assist installation - dda posts

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. Support the top and mid rails by hand before fitting the next upright post as follows:

assembling the railing system

We recommend using 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 perpendicular to the direction of the handrail.

assembling the railing system

assembling the railing system

When you assemble the rest of the structure, it may be necessary to loosen the setscrews on the already constructed fittings and tubing. This will make it easier to position and install 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

Using a chop saw

chop saw

Things you'll need:

  • Working saw with proper blade

  • Safety equipment (face, eye, respirator)

How to use a steel chop saw

  1. Familiarise yourself with the saw. A steel chop saw is used to cut pieces of steel and other hard materials. Different from common saws that cut wood, chop saws use abrasive disks (blades) to make cuts. When operated properly, a chop saw will make very precise cuts through steel.

  2. Install a proper blade - all chop saws essentially use the same type. The most common and 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. A badly fitted blade could cause the saw to mis-function and lead to serious injury. The blade will wear away with use, so replace it as soon as it becomes too small to continue cutting.

  3. Position your saw safely. Cutting steel is likely to involve sparks, soot and dust. To protect the work surface, place a piece of sheet metal or wet sheet of plywood under the saw itself. Make sure it is level.  

  4. Position the steel properly. It is important to allow the saw blade to work freely, so 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 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, grip the arm of the saw and press the trigger. Slowly push the arm to the material. Do not push too hard, let the saw do the work. If you see an abormal amount of dust and sparks, you are probably pushing too hard on the arm so ease up - pressing too hard will damage your blade and possibly ruin the tool's motor. When the steel has been cut, raise the arm and release the trigger.

Using an angle grinder

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 and 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, and 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.

Using a hacksaw

hacksaw

How to use a hacksaw:

  1. Measure the steel pipe length required.

  2. Mark the spot to be cut using a scriber.

  3. Firmly clamp the steel pipe on the vice, 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 pipe.

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