Weldlok Balltube Handrail

Heading NEPEAN Building & Infrastructure

NEPEAN Building & Infrastructure is a division of NEPEAN, Australias 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 brereinforced plastic (FRP). This brochure is designed to assist the architect, draughtsperson, engineer, fabricator and specier in the correct selection of our Weldlok Balltube steel handrail system.

CONTENTS Company Prole General Information Specications Installation Component Weights Ordering Information 2 3 4 4 11 11

Component Dimensions 5-10

Weldlok Balltube Handrail

2

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 nishing, 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 & Infrastructures 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.

Weldlok Balltube Specifications

Standard Duty Stanchions

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

Kickplate Mounting Brackets

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

Heavy Duty Stanchions

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

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

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

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.

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 sufxed R, those on the left-hand side are sufxed L.

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

Rails
Standard drilled openings on Balltube stanchions allow for a top rail of 32NB (42.4mm OD) and a mid-rail of 25NB (33.7mm OD). Hole sizes for 40NB (48.3mm OD) and 20NB (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.

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

Installation Instructions
1. 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.
4

Mega Ball Specications (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.

Weldlok Balltube Component Dimensions

Weldlok Balltube Standard Stanchions

457 457 560 457 560 457

560 457

457

484 (stairs) 484 (stairs) 560 (ramp) 560 (ramp)

484

484

560

560 150

150

WA

WAA

75

WA

WAA

CA

75

DIA.

560

CA

BP

BPA

BPAM

DIA.

BP

BPA

BPAM

Welded

Collar

Base Plate

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

636

560

505

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

Hand when facing up the stairs

457

457

Hand when facing up the stairs

457

457

V iew up the stairs

V iew up the stairs

R100

636

560

505

76 O

SMC

SM

SMAL

SMAR

457

457

SMC

SM
END VIEWS

SMAL

SMAR

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

R100 (End views)

SMO O

(End views) SMOAL SMOAR

505 457

457

Channel 125 x 65

O offset

SMO

Universal Beam O offset

110

SMOAL
200 250 310 360 410 460 530

SMOAR

110 110

END VIEWS 39 76 35 39

636

64 on 125 x 65 CHANNEL 64 on 125 x 65 CHANNEL

150 x 75 180 x 75 200 x 75 230 x 75 250 x 90 300 x 90 380 x 100

110 110 110 110 125 125 135

120 125 125 135 140

505 55

SMC CONVEYOR
55

SM TYPE

76

Side Mounted

35

636

SMC CONVEYOR

SM TYPE
5

Side Mounted Offset

Weldlok Balltube Component Dimensions

Weldlok Balltube Standard Single Ball Stanchions

178

SBBP

SBBP D.O.S.O.

SBSM D.R.S.O.

SBSM

254

SBSM D.L.S.O.

Single Ball Base Plate

100

Single Ball Side Mounted

100

*
SBH D.R.S.O. SBH D.L.S.O. SBW

End view

SBH

(Hand as if bolted to wall)

*Nominate dimensions Available in all base plate types

SBWA

SBWAA

Single Ball Offset Handrail

Single Ball Welded

102 18mm DIA. HOLES 100 50

*
60

146 75 x10 M.S. FLAT 65 100 x 10 M.S. FLAT

220

TYPICAL BASE PLATE

(Except type BPAM)

100

100 50

CORNER POST
(Type BP only)

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

20

6 150 75

PR

PRR

This system is mounted on road impact barriers

45

17

82

BASE OF BPAM

C-TYPE

Personnel Handrail

Standard Base Plates

6

65

Weldlok Balltube Component Dimensions

Weldlok Balltube Standard Closures, Joiners and Bends

300 300

300 300

3
300 300 457 457 R140 R140 R140 R140

0 30 00

300 300

260 260

457 457

SB

SB

Special lengths available

SBA SBA BENDS Special lengths available BENDS

R140 R140 Nominal rail size & bend angle Nominal rail size & bend angle

260 260 300 300

CB

CB

Drill 5mm holes for taper pins (Pins are for zinc plated) Drill 5mm holes taper pins (Pins are zinc plated) 260 260 300 300 150 150 Gap shown for clarity Gap shown for clarity

CBA CBA TOP TOP CLOSURES CLOSURES

CBA CBA BOTTOM BOTTOM

Nominate rail size

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

Weldlok Balltube Kickplate Mounting Brackets

14mm Dia. slotted 14mm Dia. holes slotted holes 10045 100 40 x 40 x 5 x 85 LG angle 40 x 40 x 5 x 85 LG angle

45

C Grating or Grating plateor thickness plate thickness 40 40

48

48

40

40

Dimension C (mm)
Type W C BP
C C C C C C C

C = Grating or Plate Thickness Plus 30 30 30 106* 106*

*94 when used on 125 x 65

SM SMO

Note: Kickplate mounting brackets are an optional extra

BP

BP

SM SM
7

SMO SMO

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

DRILLED BOTTOM SIDE ONLY

CORNER POST

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

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

Weldlok Balltube Chain Hooks

5mm CHAIN 35

8mm DIA.

50 5mm CHAIN

DETAIL OF HOOK

D.O.S.O. STANCHIONS WITH CHAIN HOOKS

Specify whether top rail only or both rails 5mm heavy duty chain available on request

Weldlok Balltube Component Dimensions

Weldlok Balltube Multi Ball Stanchions

* * *

*
BP BPAM

* 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

SM

SMO

Weldlok Balltube Handrail Accessories

32NB 32NB 100 100 25NB 70 25NB 70 R140 300

SELF CLOSING GATE

2000 max. 60

900

120

1017

2170 40 (Light not included)

*600 MIN. *1500 MAX.

Nominate width

100 CRS. OF 12 DIA. BARS Also available for ramps & stairs

BARRIER FENCING PANEL

LIGHT POLE

Weldlok Balltube Mega Ball Component Dimensions

Weldlok Balltube Mega Ball Stanchions

450

450

450

180

550

550

= 7 MAX.

= 7 MAX.

105

725

180

DIA.

MOF
100 20 DIA. HOLES

200

150 SQR.

MAM

MCR

MSM

MSAM

76mm O.D. 450 450 76mm O.D. 1000

TYPICAL BASE PLATE

(16mm thick)

76mm O.D.

550

76 O.D.
TYPICAL

550

POST

100
*

MBP

MW

MSBW

Weldlok Balltube Mega Ball Closures and Bends

76mm O.D. 150mm
RADIUS

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

MMBW

MSBBP

400

76mm O.D. 150mm RADIUS

76mm O.D. 76mm O.D.

TYPICAL

450

40

400 76mm O.D.

400

150mm RADIUS

Horizontal closure bend

2000mm MAX.

STANDARD 90 BEND

ANGLE BEND
400 = 7MAX

MEGA BALL PANEL

76mm O.D. 150mm

RADIUS

450

76

mm

O.D

400

150mm RADIUS

HORIZONTAL CLOSURE BEND

10

ANGLE CLOSURE BEND

Weldlok Balltube Handrail Weights

Weldlok Balltube Stanchions

Type BP BPA C CA W WA-WAA SM SMO SMA SMC SMOA BPAM SBW SBWA SBBP SBSM SBH 3.2mm Wall Thickness 4.8kg 4.8kg 4.9kg 4.9kg 3.9kg 3.9kg 5.0kg 5.3kg 4.9kg 4.9kg 5.3kg 4.5kg 3.9kg 3.9kg 1.7kg 2.0kg 1.3kg 4.0mm Wall Thickness 5.3kg 5.3kg 5.4kg 5.4kg 4.4kg 4.4kg 5.6kg 5.9kg 5.4kg 5.4kg 5.9kg 5.0kg 4.4kg 4.4kg 2.0kg 2.3kg

Ordering Information
Important When Ordering 1. Nominate duty of stanchions (standard or heavy duty). 2. Specify nish 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 page7). Note: Right-hand location of kickplate is standard and will be supplied on RH unless otherwise nominated.
Weight 1.8kg 1.4kg 0.9kg 2.8kg 2.2kg 2.8kg 2.2kg

Bends & Closures

Type SB, SBA N.B. 32 25 20 32 25 32 25

Mega Ball Stanchions

MAM MCR MSM MSAM MBP MW MSBW MOF RAIL Standard Duty RAIL Heavy Duty Type N.B. 65 65 65 65 65 65 65 65 65 65 Weight 11.50kg 10.50kg 12.65kg 12.65kg 11.50kg 8.70kg 8.10kg 5.30kg 6.51 kg/m 7.90 kg/m

SB, SBA SB, SBA CB CB CBA CBA

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.

Rails & Kickplates

Type 32 N.B. Rail 25 N.B. Rail 20 N.B. Rail 100 x 6 Kickplate 3.2 kg/m 2.5 kg/m 1.6 kg/m 4.8 kg/m Weight

Weights based on wall thickness of 3.6mm

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, February 2013.

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NEPEAN Building & 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: bi@nepean.com BRANCHES NSW (COFFS HARBOUR) 47 Wingara Drive (PO Box 396) Coffs Harbour, NSW 2450 Australia P: + 61 2 6652 4100 F: + 61 2 6652 2285 E: coffs.bi@nepean.com QLD 967 Nudgee Road (PO Box 283) Banyo QLD 4014 P: + 61 7 3633 1333 F: + 61 7 3633 1313 E: qld.bi@nepean.com VIC 171 Derrimut Drive Derrimut VIC 3030 Australia P: + 61 3 9394 1001 F: + 61 3 9394 1441 E: vic.bi@nepean.com WA 98 Campbell Street Belmont WA 6104 (PO Box 267 Cloverdale, WA 6985) P: + 61 8 9478 1034 F: + 61 8 9277 7742 E: wa.bi@nepean.com 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: nepean.asia@nepean.com www.nepean.com
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