Weldlok Balltube Handrail

Weldlok Balltube Handrail ® Heading NEPEAN™ Building & Infrastructure NEPEAN Building & Infrastructure is a division of NEPEAN, Australia’s largest...
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Weldlok Balltube Handrail ®

Heading NEPEAN™ Building & Infrastructure

NEPEAN Building & Infrastructure is a division of NEPEAN, Australia’s largest privately owned engineering, mining services and industrial manufacturing organisation.

Through our renowned Weldlok® brand, NEPEAN Building & Infrastructure manufactures and supplies an extensive range of fabricated gratings and handrails. These products include forgebar grating and walkways, specialist drainage grates, and handrail systems manufactured from steel and aluminium. We also supply walkway grating manufactured from fibrereinforced plastic (FRP). This brochure is designed to assist the architect, draughtsperson, engineer, fabricator and specifier in the correct selection of our Weldlok Balltube® steel handrail system.

Weldlok Balltube® Handrail 2

CONTENTS Company Profile

2

General Information

3

Specifications

4

Installation

4

Component Dimensions 5-10 Component Weights

11

Ordering Information

11

Weldlok Balltube® Handrail System

Weldlok Balltube® Handrail The Weldlok Balltube® Handrail System sets the standard for time and cost saving in the installation of walkways, stairs and ladders. The modular Weldlok Balltube® system allows speedy erection and finishing, with a minimum of onsite welding, providing considerable savings in time and labour costs. Components delivered to site include fully galvanised stanchions, rails, bends, kickplates, slip-joints, closures, etc., ready for trouble-free erection. NEPEAN Building & Infrastructure’s unmatched resources include the best modern equipment and manufacturing techniques, including a galvanising facility, all under one roof. These facilities are backed by advanced quality control systems and our team of experienced personnel, ensuring immediate response to customer needs, quick delivery and co-ordinated after-sales service. We can also supply a total package, including Weldlok Balltube® Handrail System, forgebar gratings, stair treads and walkway modules. The Weldlok Balltube® Handrail System is designed and manufactured to the requirements of Australian Standard AS1657-1992.

3

Weldlok Balltube® Specifications

Standard Duty Stanchions Standard duty stanchions are manufactured from 40 NB tubing (48.3mm OD x 3.2mm wall thickness).

Heavy Duty Stanchions Heavy duty stanchions are manufactured from 40 NB tubing (48.3mm OD x 4.0mm wall thickness).

Stanchion Pitching Australian Standard AS1657:1992 recommends a maximum pitching of 2 metres for stanchions.

Stanchion Handing Handing of stanchions is from point of view on stairway or platform, facing the inside of the stanchion. Those on the right-hand side are suffixed ‘R’, those on the left-hand side are suffixed ‘L’.

Rails Standard drilled openings on Balltube stanchions allow for a top rail of 32 NB (42.4mm OD) and a mid-rail of 25 NB (33.7mm OD). Hole sizes for 40 NB (48.3mm OD) and 20 NB (26.9mm OD) rails in either top rail or mid-rail positions are also available. Rails are supplied in medium gauge, with a maximum length of 6.5m.

Kickplate Mounting Brackets Manufactured from 40mm x 40mm x 5mm angle x 85mm long, with two 14mm diameter slotted holes, to suit 100mm kickplate.

Kickplates Standard kickplates are 100mm x 6mm in 6m lengths. Other sizes available on request.

Base Plates All base plates (except BPAM type) are 75mm x 146mm x 10mm with 18mm diameter holes at 102mm centres. BPAM base plates are 65mm x 172mm x 10mm with 18mm diameter holes at 126mm centres. Note: Special base plates can be made to order.

Finish Standard finish is hot-dip galvanised to AS/NZS4680:1999. Untreated finish available on request.

Specials Variations on standard stanchions and fittings can be manufactured to individual requirements.

Installation Instructions 1. Loosely bolt stanchions to structure. 2. Feed top rails and mid-rail through ball joints.

Mega Ball Specifications (Refer page 10) Standard Duty Stanchions – 65 NB (76.1mm OD x 3.6mm wall thickness). Heavy Duty Stanchions – 65 NB (76.1mm OD x 4.5mm wall thickness). Spheres – 125mm OD, to suit 76.1mm OD piping. Rails – Same duty as stanchions. Supplied in 6.5m lengths. Base Plates – 150mm x 150mm. Thickness 16mm. Holes 20mm OD. Special Base Plates – Made to requirements. Finish – Hot-dip galvanised or untreated.

3. Where top or mid-rails join, use slip joint. 4. Drill for taper pins. (Ensure the join is inside the ball unit, where possible.) 5. Tighten nuts and bolts on stanchions. 6. Run approximately 25mm (1 inch) of weld on side or top where ball units join top and mid-rails (not required when using tapered pins). 7. Bends and corners to be fully welded then ground and primed with zinc-rich paint.

4

Weldlok Balltube® Component Dimensions

θ°

457 θ°

θ°

560

6

C

DIA.

CA

6

WAA

150

WA

560 150

484

560

W

75

75

W

WA

WAA

C

Welded

θ°

θ°

θ°

θ°

θ°

θ° 484 (stairs) 484 (stairs) 560 (ramp) 560 (ramp)

θ°

θ°

θ° 560 457

θ° 560 457

θ°

484

560 457

457

457

Weldlok Balltube® Standard Stanchions

θ°

θ°

BP

BPA

BPAM

BP

BPA

BPAM

DIA.

CA

Collar

Base Plate

457

θ°

V iew up the stairs

560 (stairs) 560 (stairs) 457 635 (ramp) 635 (ramp)

Hand when facing up the stairs

457

457

θ°

V iew up the stairs

560

θ°

560

76

SMAL

SM

SMAR

SMAL

457

457

SMC

SM

457 560 (stairs) 560 (stairs) 635 (ramp) 635 (ramp)

SMC

636

505

636

505

457

θ°

Hand when facing up the stairs

SMAR

35

SMC CONVEYOR 55

Side Mounted

35

SM TYPE

76

457

180 x 75 200 x 75

64 on 125 x 65 CHANNEL

35

SMC CONVEYOR

Universal Beam “O” offset

636 76

SMO

110

5

SMOAL 200

SMOAR

110

250

110

110

310

120

110

360

125

230 x 75

110

410

125

250 x 90

125

460

135

300 x 90

125

530

140

380 x 100

135

Side Mounted Offset

SM TYPE

“O”

“O” offset 110

64 on 125 x 65 CHANNEL

“O ”

“O”

(End views) SMOAL SMOAR

150 x 75

125 x 65

R100 (End views)

SMO “O ”

Channel

636

505 457 505 55

END VIEWS 35

“O ”

“O ”

64 on 125 x 65 76 OFFSET (See table) CHANNEL 64 on OFFSET 125 x 65 Offset “O” (mm) (See table) CHANNEL

END VIEWS

R100

Weldlok Balltube® Component Dimensions

254

178

Weldlok Balltube® Standard Single Ball Stanchions

SBBP

SBBP D.O.S.O.

Single Ball Base Plate

SBSM D.R.S.O.

SBSM

SBSM D.L.S.O.

Single Ball Side Mounted

100

θ°

100

θ°

*

*

θ°

SBH D.L.S.O.

SBH D.R.S.O.

(Hand as if bolted to wall)

Single Ball Offset Handrail

SBW

SBWAA

SBWA

*Nominate dimensions Available in all base plate types

Single Ball Welded 100 50

18mm DIA. HOLES

100 50

102

65

SBH

End view

*

75 x10 M.S. FLAT

100

TYPICAL BASE PLATE (Except type BPAM)

20

220

60

146 65

CORNER POST

100 x 10 M.S. FLAT

(Type BP only)

18mm DIA. HOLES 50 x 10 M.S. FLAT

θ°

BASE OF BPAM

Personnel Handrail

150

82 2

This system is mounted on road impact barriers

17

PRR

45

PR

6

18mm DIA. HOLES

Standard Base Plates 6

75

C-TYPE

Weldlok Balltube® Component Dimensions

Weldlok Balltube® Standard Closures, Joiners and Bends 300 300

300 300

300 300

0 30 00

3 300 300 θ° θ°

260 260

CB

R140 R140

SB

457 457

457 457

R140 R140

SB

SBA SBA BENDS Special lengths available BENDS

Special lengths available

Drill 5mm holes for taper pins (Pins are for zinctaper plated) Drill 5mm holes pins (Pins are zinc plated)

260 260

CB

R140 R140 Nominal rail size & bend angle Nominal rail size & bend angle θ°

θ°

300 300

260 260

CBA CBATOP TOP

300 300

150

RAIL JOINER RAIL JOINER (SLIP JOINT) (SLIP JOINT) Nominate rail size

CBA CBA BOTTOM BOTTOM

CLOSURES CLOSURES

150

Gap shown clarity Gapfor shown for clarity

Nominate rail size

Weldlok Balltube® Kickplate Mounting Brackets 14mm Dia. slotted 14mm Dia. holes slotted holes

45

10045 100

40 x 40 x 5 x 85 LG 40 xangle 40 x 5 x 85 LG angle

“C”

“C”

“C”

“C”

48

48

Grating or Grating plateor thickness plate thickness 40

40

40

40

Dimension “C” (mm) Type

“C”

W

W

“C”

“C”

C

C

“C”

“C”

BP

“C”

BP

Note: Kickplate mounting brackets are an optional extra

“C”

SM SM 7

“C” “C”

SMO SMO

“C”

“C” = Grating or Plate Thickness Plus

W

30

C

30

BP

30

SM

106*

SMO

106* *94 when used on 125 x 65

Example: If grating is 25mm deep then “C” Dimension = 55mm for types W, C, & BP.

Weldlok Balltube® Component Dimensions

Weldlok Balltube® Special Drilling for Rails

90°

DRILLED RIGHT HAND SIDE ONLY

DRILLED LEFT HAND SIDE ONLY

DRILLED TOP SIDE ONLY

CORNER POST

DRILLED BOTTOM SIDE ONLY

DRILLED ONE SIDE ONLY (D.O.S.O.)

These combinations of drilling are available on full range of standard stanchions

Weldlok Balltube® Chain Hooks

8mm DIA.

5mm CHAIN 35

50

DETAIL OF HOOK

5mm CHAIN

D.O.S.O. STANCHIONS WITH CHAIN HOOKS Specify whether top rail only or both rails 5mm heavy duty chain available on request

8

Weldlok Balltube® Component Dimensions

Weldlok Balltube® Multi Ball Stanchions

* * *

*

θ°

BP

BPAM

SM

* Specify number of balls, pitching & height required of stanchion (150mm minimum centres)

SMO

Multi ball stanchions are available in any of the range of Balltube stanchion configurations

Weldlok Balltube® Handrail Accessories 32NB

32NB

300

100 100 R140

25NB

25NB 70

70

*600 MIN. *1500 MAX.

2170

Nominate width

SELF CLOSING GATE 60

120

1017

900

2000 max.

40

100 CRS. OF 12 DIA. BARS

BARRIER FENCING PANEL

LIGHT POLE

Also available for ramps & stairs

(Light not included)

9

Weldlok Balltube® Mega Ball Component Dimensions

Weldlok Balltube® Mega Ball Stanchions θ°

θ°

450

450

450

180

θ°

180

θ°

θ°= 7° MAX.

725

550

550

θ°= 7° MAX.

105

DIA.

MOF

200

θ°

76mm O.D.

(16mm thick)

1000

76mm O.D.

76 O.D. TYPICAL

*

76mm O.D.

MMBW

MSBW

MW

MSBBP

*as required *specify number of balls, pitching & height required of stanchion (180mm minimum) (300mm min. centres)

Weldlok Balltube® Mega Ball Closures and Bends 400

76mm O.D. 150mm RADIUS

450

150mm

Horizontal closure bend

*

*

MBP

RADIUS

76mm O.D.

550

550

POST

100

TYPICAL BASE PLATE

*

450

450

150 SQR.

MSAM

MSM

MCR

MAM

20 DIA. HOLES

100

400 76mm O.D.

0

40

76mm O.D.

2000mm MAX.

MEGA BALL PANEL

76mm O.D.

ANGLE BEND

STANDARD 90° BEND

TYPICAL

400

76mm O.D. 150mm RADIUS

θ°= 7°MAX θ° 450

400

HORIZONTAL CLOSURE BEND 10

150mm RADIUS

θ°

400

mm

76

.

O.D

150mm RADIUS

ANGLE CLOSURE BEND

Weldlok Balltube® Handrail Weights

Weldlok Balltube® Stanchions 3.2mm Wall Thickness

4.0mm Wall Thickness

BP

4.8kg

5.3kg

BPA

4.8kg

5.3kg

C

4.9kg

5.4kg

CA

4.9kg

5.4kg

Type

W

3.9kg

4.4kg

WA-WAA

3.9kg

4.4kg

SM

5.0kg

5.6kg

SMO

5.3kg

5.9kg

SMA

4.9kg

5.4kg

SMC

4.9kg

5.4kg

SMOA

5.3kg

5.9kg

BPAM

4.5kg

5.0kg

SBW

3.9kg

4.4kg

SBWA

3.9kg

4.4kg

SBBP

1.7kg

2.0kg

SBSM

2.0kg

2.3kg

SBH

1.3kg

1. Nominate duty of stanchions (standard or heavy duty). 2. Specify finish required for stanchions (galvanised or untreated). 3. Nominate type of stanchion (see codes in this brochure). 4. State top rail and mid-rail sizes required in nominal bore pipe sizes.

N.B.

Weight

MCR

65

10.50kg

MSM

65

12.65kg

MSAM

65

12.65kg

MBP

65

11.50kg

MW

65

8.70kg

MSBW

65

8.10kg

MOF

65

5.30kg

RAIL – Standard Duty

65

6.51 kg/m

RAIL – Heavy Duty

65

11.50kg

7.90 kg/m

Weights based on wall thickness of 3.6mm

5. If kickplate mounting bracket is required, nominate handing and dimension “C” (refer to page 7). Note: Right-hand location of kickplate is standard and will be supplied on RH unless otherwise nominated.

Bends & Closures N.B.

Weight

SB, SBA

25

1.4kg

SB, SBA

20

0.9kg

CB

32

2.8kg

CB

25

2.2kg

CBA

32

2.8kg

CBA

25

2.2kg

SB, SBA

Type

65

Important When Ordering

Type

Mega Ball Stanchions MAM

Ordering Information

32

1.8kg

Rails & Kickplates Type

Weight

32 N.B. Rail

3.2 kg/m

25 N.B. Rail

2.5 kg/m

20 N.B. Rail

1.6 kg/m

100 x 6 Kickplate

4.8 kg/m

6. If stanchions are offset type, state “O” dimension from selection table on page 5. 7. If stanchions are angled type, specify angle of elevation. 8. If stanchions are to be drilled one side only, nominate handing. 9. Any variations to normal stanchions should be noted and drawing supplied. 10. Supply list of all joiners and split pins, rails, kickplates, etc.

The above weights for rails and bends are based on medium gauge pipe.

Information contained in this brochure is supplied in good faith and with the view to assist the user in the correct selection of our products. While every care is taken to ensure that the information contained in this brochure is correct, no warranty is made nor is any condition expressed or implied. As the use of products sold is beyond our control, a condition of purchase is that the purchaser accepts responsibility for ensuring that products purchased are suitable for the intended use. NEPEAN Building & Infrastructure is committed to continual product improvement and therefore reserves the right to change details and designs without notice. © NEPEAN Building & Infrastructure, September 2013.

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NEPEAN Building & Infrastructure HEAD OFFICE

VIC

NSW

171 Derrimut Drive Derrimut VIC 3030 Australia

117-153 Rookwood Road (PO Box 57) Yagoona NSW 2199 Australia P: + 61 2 9707 5000 F: + 61 2 9790 1013 E: [email protected] BRANCHES NSW (COFFS HARBOUR) 47 Wingara Drive (PO Box 396) Coffs Harbour, NSW 2450 Australia

P: + 61 3 9394 1001 F: + 61 3 9394 1441 E: [email protected] WA 98 Campbell Street Belmont WA 6104 (PO Box 267 Cloverdale, WA 6985) P: + 61 8 9478 1034 F: + 61 8 9277 7742 E: [email protected] CHINA

P: + 61 2 6652 4100 F: + 61 2 6652 2285 E: [email protected] QLD 967 Nudgee Road (PO Box 283) Banyo QLD 4014 P: + 61 7 3633 1333 F: + 61 7 3633 1313 E: [email protected]

12F Digital Mansion 16 Huizhandonglu Road Torch Zone, Zhongshan City Guangdong Province P.R. China 528437 P: + 86 760 8992 3558 F: + 86 760 8992 3559 M: + 86 159 1334 3700 (China) M: + 61 419 782 122 (Australia) E: [email protected] www.nepean.com

September 2013 – Supersedes previous editions

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