How To Install Barrier Handrail System

Installing Barrier handrail System

Building Your Interclamp Handrail System

The Interclamp barrier handrail system has been designed to be easy to install, utilising a common selection of tools. NONE of these parts require welding and can be put together to create an impressive handrail design in a matter of hours. As well as supplying in standard galvanised form, barrier rail parts are also available in a range of powder coat colours, including: Yellow - RAL1018 (necessary for DDA regulations); Red - RAL3020; Blue - RAL5002; Green - RAL6018; Black - RAL9005; and White - RAL9016.

When it comes to the installation of a barrier handrail system, the barrier may require cutting to size. This is recommended for an optimum fit and can generally be achieved with one of the three following cutting methods.

Cutting Handrails

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.

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.


Things you'll need:

  • Tape measure
  • Scriber
  • Vice/Clamps
  • Work Bench/Surface
  • Hack Saw (Of Course)
  • 40 grit flapper wheel


  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.

Intuitive Barrier Handrail System With Near Limtless Possibilities

At Pear Stairs we offer far more than barrier handrail systems, our Stair Parts store offers a vast choice of parts in a variety of materials and timbers including oak, ash, pine (both Scandinavian and southern yellow), sapele, walnut, idigbo and hemlock stair parts. We also supply a white primed option, which can save valuable surface preparation time on site when the stairs are to be painted. As the timber has already been treated with primer, you will just need to apply an undercoat and top coat. If you are interested in a complete bespoke staircase, contact our design team on 01938 553311 or email Alternatively, have a play with the StairCreator, our online planning tool. The StairCreator renders your design in full 3D, letting you experiemnt with different designs, specifications and materials, while tracking the cost of the StairCase with a quote for your design.