weldlok balltube handrail

Weldlok Balltube® Handrail

HeadingNEPEAN™ Building & Infrastructure

CONTENTS

Company Profile 2

General Information 3

Specifications 4

Installation 4

Component Dimensions 5-10

Component Weights 11

Ordering Information 11

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 fibre-reinforced 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.

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

2

Weldlok Balltube® Handrail

3

Weldlok Balltube® Handrail System

Weldlok Balltube® HandrailThe 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 on-site 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.

4

Weldlok Balltube® Specifications

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

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

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

Stanchion HandingHanding 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’.

RailsStandard 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 BracketsManufactured from 40mm x 40mm x 5mm angle x 85mm long, with two 14mm diameter slotted holes, to suit 100mm kickplate.

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

Base PlatesAll 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.

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

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

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.

Installation Instructions1. Loosely bolt stanchions to structure.

2. Feed top rails and mid-rail through ball joints.

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.

5

Weldlok Balltube® Component Dimensions

457

484

560

θ°

W

457

560

150

75 6

θ°

θ°

560

457

484

(sta

irs)

560

(ram

p)

θ° θ°

θ°

457

505

55 35

39 636

457

END VIEWS

SMC CONVEYOR SM TYPE

457

505

636

560

(sta

irs)

635

(ram

p)

560

560

(sta

irs)

635

(ram

p)

457

θ°

θ°

Hand when facing up the stairs

SMC SM SMAL SMAR

457

R100

76

V iew up the stairs

(End views) 64 on

125 x 65 CHANNEL

OFFSET (See table)

SMO SMOAL SMOAR

“O ”

“O ”

“O ”

θ°

DIA.

θ°

64 on 125 x 65

CHANNEL 76

WA C CA BP BPA BPAM WAA

457

484

560

θ°

W 45

7 56

0 15

0 75

6

θ°

θ°

560

457

484

(sta

irs)

560

(ram

p)

θ° θ°

θ°

457

505

55 35

39 636

457

END VIEWS

SMC CONVEYOR SM TYPE

457

505

636

560

(sta

irs)

635

(ram

p)

560

560

(sta

irs)

635

(ram

p)

457

θ°

θ°

Hand when facing up the stairs

SMC SM SMAL SMAR

457

R100

76

V iew up the stairs

(End views) 64 on

125 x 65 CHANNEL

OFFSET (See table)

SMO SMOAL SMOAR

“O ”

“O ”

“O ”

θ°

DIA.

θ°

64 on 125 x 65

CHANNEL 76

WA C CA BP BPA BPAM WAA

Weldlok Balltube® Standard Stanchions

Welded Collar Base Plate

Side Mounted Side Mounted Offset

Offset “O” (mm)

Channel “O” offset Universal Beam “O” offset125 x 65 110 200 110150 x 75 110 250 110180 x 75 110 310 120200 x 75 110 360 125230 x 75 110 410 125250 x 90 125 460 135300 x 90 125 530 140380 x 100 135

6


Weldlok Balltube® Standard Single Ball Stanchions

254 178

SBBP SBBP D.O.S.O. SBSM

D.R.S.O. SBSM SBSM

D.L.S.O.

θ° θ°

θ°

* *

100

100

End view (Hand as if bolted to wall)

SBH SBH D.R.S.O.

SBH D.L.S.O.

SBW SBWA SBWAA * Nominate dimensions

Available in all base plate types

60

220

100

20

50 x 10 M.S. FLAT

18mm DIA. HOLES

*

PR PRR This system is mounted on

road impact barriers

102

146

100

65

65

100

18mm DIA. HOLES

75

150

6

172

82

45

θ°

18mm DIA. HOLES

TYPICAL BASE PLATE (Except type BPAM)

CORNER POST (Type BP only)

BASE OF BPAM C-TYPE

75 x 10 M.S. FLAT

50

50

100 x 10 M.S. FLAT

Single Ball Base Plate Single Ball Side Mounted

Single Ball Offset Handrail Single Ball Welded

Personnel Handrail Standard Base Plates

7

Weldlok Balltube® Standard Closures, Joiners and Bends

300

457

R140

260θ°

260

457

300260

300 Gap shownfor clarity

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

150

CB

CBATOP

CBABOTTOMCLOSURES

RAIL JOINER(SLIP JOINT)

Nominate rail size

“C” “C” “C”“C”

W C BP SM SMO

4040

48“C”

40 x 40 x 5 x 85 LGangle

14mm Dia. slotted holes

10045

“C”

Grating or plate thickness

“C”

300

300 R140

300300

θ° R140

BENDSSpecial lengths available

SB SBA

Nominal rail size& bend angle

300

457

R140

260θ°

260

457

300260

300 Gap shownfor clarity

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

150

CB

CBATOP

CBABOTTOMCLOSURES

RAIL JOINER(SLIP JOINT)

Nominate rail size

“C” “C” “C”“C”

W C BP SM SMO

4040

48“C”

40 x 40 x 5 x 85 LGangle

14mm Dia. slotted holes

10045

“C”

Grating or plate thickness

“C”

300

300 R140

300300

θ° R140

BENDSSpecial lengths available

SB SBA

Nominal rail size& bend angle

Weldlok Balltube® Kickplate Mounting Brackets

Note: Kickplate mounting brackets are an optional extra

Dimension “C” (mm)

Type “C” = Grating or Plate Thickness Plus

W 30C 30BP 30SM 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.


8


Weldlok Balltube® Special Drilling for Rails

8mm DIA.

35

50

DETAIL OF HOOK

D.O.S.O. STANCHIONS WITH CHAIN HOOKSSpecify whether top rail only or both rails

5mm heavy duty chain available on request

5mm CHAIN

5mm CHAIN

DRILLEDRIGHT HAND

SIDE ONLY

DRILLEDLEFT HANDSIDE ONLY

DRILLEDTOP

SIDE ONLY

DRILLEDBOTTOM

SIDE ONLY

CORNERPOST

These combinations of drilling are available on full range of standard stanchionsDRILLED ONE SIDE ONLY (D.O.S.O.)

°90

Weldlok Balltube® Chain Hooks

9

θ°

*

*

*

*

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

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

SELF CLOSING GATE

BARRIER FENCING PANEL Also available for ramps & stairs

*1500 MAX.

32NB

*600 MIN. Nominate width

32NB

25NB 25NB

70 70

120

900

100 CRS. OF 12 DIA. BARS

2000 max.

100 300

100

60

1017

40

2170

LIGHT POLE(Light not included)

R140

Weldlok Balltube® Multi Ball Stanchions

Weldlok Balltube® Handrail Accessories


10

Weldlok Balltube® Mega Ball Component Dimensions

180

180

MOF

100

100

150

SQR.

20 DIA.HOLES

TYPICAL BASE PLATE

*

76mm O.D.

MSBBP

*

*

*

1000

550

450

450

550 POST

76 O.D.TYPICAL

76mm O.D.

76mm O.D.

MBP MW MSBW MMBW

θ°

θ°

θ°

θ°= 7° MAX. θ°= 7° MAX.

450

550

450

550

450

725

θ°

θ°

200

105DIA.

MAM MCR MSM MSAM

*specify number of balls, pitching & height required of stanchion

(300mm min. centres)

*as required(180mm minimum)

(16mm thick)

MEGA BALL PANEL

STANDARD 90 BEND° ANGLE BEND

ANGLE CLOSURE BENDHORIZONTAL CLOSURE BEND

400

150mm RADIUS

76mm O.D.

76mm O.D.

400

400 76mm O.D.

76mm O.D.

150mm RADIUSθ°

θ° = 7° MAX

2000mm MAX.

150mm RADIUS

76mm O.D.

Horizontal closure bend

76mm O.D.400

450

76mm O.D.TYPICAL

400

450

θ°

150mm RADIUS

150mm RADIUS

400

Weldlok Balltube® Mega Ball Stanchions

Weldlok Balltube® Mega Ball Closures and Bends

11

Weldlok Balltube® Handrail Weights

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, February 2013.

Type3.2mm

Wall Thickness

4.0mm Wall

ThicknessBP 4.8kg 5.3kgBPA 4.8kg 5.3kgC 4.9kg 5.4kgCA 4.9kg 5.4kgW 3.9kg 4.4kgWA-WAA 3.9kg 4.4kgSM 5.0kg 5.6kgSMO 5.3kg 5.9kgSMA 4.9kg 5.4kgSMC 4.9kg 5.4kgSMOA 5.3kg 5.9kgBPAM 4.5kg 5.0kgSBW 3.9kg 4.4kgSBWA 3.9kg 4.4kgSBBP 1.7kg 2.0kgSBSM 2.0kg 2.3kgSBH 1.3kg

Weldlok Balltube® Stanchions

Mega Ball Stanchions

Type N.B. WeightMAM 65 11.50kgMCR 65 10.50kgMSM 65 12.65kgMSAM 65 12.65kgMBP 65 11.50kgMW 65 8.70kgMSBW 65 8.10kgMOF 65 5.30kgRAIL – Standard Duty

65 6.51 kg/m

RAIL – Heavy Duty

65 7.90 kg/m

Weights based on wall thickness of 3.6mm

Type N.B. WeightSB, SBA 32 1.8kgSB, SBA 25 1.4kgSB, SBA 20 0.9kgCB 32 2.8kgCB 25 2.2kgCBA 32 2.8kgCBA 25 2.2kg

Type Weight32 N.B. Rail 3.2 kg/m25 N.B. Rail 2.5 kg/m20 N.B. Rail 1.6 kg/m100 x 6 Kickplate 4.8 kg/m

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

Bends & Closures

Rails & Kickplates

Ordering InformationImportant When Ordering

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.

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.

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.

NEPEANBuilding & Infrastructure

HEAD OFFICE

NSW

117-153 Rookwood Road (PO Box 57) Yagoona NSW 2199 Australia

P: + 61 2 9707 5000 F: + 61 2 9790 6145 E: [email protected]

BRANCHES

NSW (COFFS HARBOUR)

47 Wingara Drive (PO Box 396) Coffs Harbour, NSW 2450 Australia


QLD

967 Nudgee Road (PO Box 283) Banyo QLD 4014


VIC

171 Derrimut Drive Derrimut VIC 3030 Australia


WA

98 Campbell Street Belmont WA 6104 (PO Box 267 Cloverdale, WA 6985)


CHINA

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

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weldlok balltube handrail

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