Custom handrail systems

What it is

Not every handrail fits a standard kit. Curved platforms around tanks and silos, raked rails on stairs with varying pitch, landings with odd angles, architectural balustrades with special infill, and rails that must follow existing structures all need handrails designed and fabricated for the job. World Steel's custom handrail systems are made exactly for that: each run is detailed from the project geometry, built in the factory and delivered ready to bolt or weld into place.

Custom handrails are usually part of a larger steel package – stairs, spiral stairs, platforms, pipe racks or architectural steelwork – and are modelled together with it, so stanchion positions, fixings and splices match the supporting steel. Where standard runs are enough, they can be combined with WS modular guardrail or welded industrial handrails on the same project.

Types and options

For public and accessible routes see also architectural balustrades and accessible handrails.

Design and compliance

Heights, openings and loads follow the governing code. Industrial access in the US follows OSHA 29 CFR 1910.29 – top rail 42 in ± 3 in, 200 lbf on the top rail, and stair handrails 30–38 in. Public buildings follow IBC 1015 (guards at least 42 in with a 4 in sphere rule) and IBC 1014 (handrails 34–38 in). In Australia, AS 1657 sets guardrails at 900–1100 mm for plant access, while the NCC requires barriers of at least 1000 mm (865 mm along stairs) with no opening passing a 125 mm sphere, and AS 1428.1 handrails of 30–50 mm diameter on accessible routes. In Europe, EN ISO 14122-3 requires guard-rails of at least 1100 mm with a knee-rail and toe-plate on machinery access.

Barrier loads come from ASCE 7, AS/NZS 1170.1 Table 3.3 or EN 1991-1-1 Table 6.12, and glass infill is designed to AS 1288 or the national rules for glass in buildings. World Steel checks stanchion sizes, spacing and fixings for the specified loads or works to the engineer's design, and fixings into concrete are designed to ACI 318 Chapter 17, AS 5216 or EN 1992-4. See design loads.

Fabrication and finishing at World Steel

Each run is modelled in Tekla with the structure it sits on, producing shop drawings for every rail section and an IFC model for coordination. Tube is rolled or bent to the radius in the model, stanchions and infill are welded on jigs, and joints on graspable rails are ground smooth. Welding follows qualified procedures under World Steel's ISO 3834-2 system and the AS/NZS 5131 CC3 and EN 1090-2 frameworks; stainless rails are welded to AWS D1.6 or AS/NZS 1554.6 procedures and pickled and passivated.

Where specified, complex runs are trial fitted to their stairs or platforms in the factory before finishing. Carbon steel rails are hot-dip galvanised by qualified galvanisers, with vent and drain holes detailed in the model, then painted or powder coated where a colour is required. Rails are marked, wrapped and packed by area for export shipping.

Installation and specifying

• Rails are supplied in sections sized for handling and galvanising, with bolted or site-welded splices as detailed.
• Install stanchions to the setting-out on the erection drawings, then align and fix the rail sections.
• Repair any site-cut or welded galvanising with zinc-rich paint per ASTM A780, AS/NZS 4680 or EN ISO 1461.
• For a quotation send architectural or structural drawings or the model, governing code, infill type, material, finish and mounting details.