SAFERAIL

STANCHIONS 1 BALL CENTRES 2 90 DEGREE 11 3 HANDRAIL INTERNAL

Tubular 25B, 32NB, 40 NB 450mm (Typically for stairs) BEND 25NB, 32NB & 40NB EXPANDING
Solid Dia. 32mm & 38mm 500mm & 533mm CONNECTOR
7 HANDRAIL CONNECTOR
Internal expanding
type or dowel type
DOWEL
CONNECTOR

6
KNEE RAIL
4 25NB, 32NB
& 40NB 5 TOE PLATE
100x5mm, 130x5mm,
150x5mm

PLATFORM 10
RETURN BEND

KCB1 8
Internal
Connector

BASEPLATES 8 KCB3 9 STANCHION CONNECTOR

Side Mounted Type A and FX Straight K25 and K40 stanchion 8 KCB2
Top Mounted Type D, NX Connector connectors used to secure the External
and GX stanchions to the toe plate Connector
(top and/or bottom).

INTRODUCTION TERMINOLOGY
1. Stanchion – Upright post comprising 5. Toe Plate – A 5mm thick flat bar at 8. Toe Plate Connectors – Method of
Lionweld Kennedy, part of Hill & Smith PLC, are a market-leading supplier of safe, compliant of a shank (tube) and balls - to accept the base of the handrail system to form a fixing two lengths of toe plate together.
and sustainable steel and GRP access products. We have been proudly manufacturing steel handrail - and a baseplate to facilitate barrier to prevent objects falling off the
access products in the UK for over 100 years and are experts in our industry. fixing to supporting structure. Tube sizes walkway and to achieve the requirement 9. Stanchion Connector – K25 and K40
vary and ball spacing is set to meet of a maximum 500mm gap in any part of stanchion connectors, used to secure the
required industry standards. the system. stanchions to the toe plate (top and/or
Steel Handrail System 2. Ball Centres – The vertical distance 6. Stanchion Pitch – The distance
bottom).

between the centre line of the handrail between stanchions determined by load 10. Platform Return Bend
Saferail is a steel industrial handrailing shapes to allow simple handrail systems accordance with British and European and knee rail. requirements and stanchion section size.
system used extensively throughout the to be pieced together with the support of standards (BS4592-0:2006+A1:2012 and 11. 90 Degree Bend
UK in a wide variety of industries and tubular or solid handrail stanchions. BS EN ISO 14122-3: 2016). 3. Handrail – The uppermost tube; for 7. Handrail Connector – Method of fixing
applications. personnel to hold onto and for support. two tubes together to form a continuous
The range consists of stanchions, handrail, handrail / knee rail. Located a maximum
Saferail can be provided as a fully gates, kick flat/toe plate and a range of 4. Knee Rail – The lower tube; to prevent of 150mm from the centre line of adjacent
fabricated system or in standard modular fixings and connectors, all designed in personnel falling from the walkway and to stanchion.
achieve the requirement of a maximum
500mm gap in any part of the system.

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DESIGN CONSIDERATIONS
BALL
BALL PLATFORM RAIL AVAILABLE BALL CENTRES LOADING REQUIREMENTS
• Design height should be 1100mm 533mm (standard offering) There are 2 main loading categories
from top of the floor. 500mm (standard offering) recommended by BS4592-
450mm (typical for Stair Rail) 0:2006+A1:2012.
• Distance between rails to create an
BALL CENTRES
BALL CENTRES

SHANK
SHANK
opening no greater than 500mm. 1. General duty of 0.36kN/m
AVAILABLE TAIL LENGTH 2. Heavy duty of 0.74kN/m

STAIR RAIL DIMENSIONS

The stanchion section size and the
Variable to suit application. loading requirement will determine the
BALL
BALL • Distance from the pitch line to the distance between stanchions - see load
centreline of the stair handrail should tables for further information.
be between 900mm – 1000mm. For quick delivery it may be possible to
utilise our stock range of stanchions.
Note: The maximum opening within any
TAIL LENGTH (VARIABLE)
TAIL LENGTH (VARIABLE)

part of the handrail system must be no

more than 500mm. Toe plate of varying
heights can be fixed to the stanchion to
ensure this is adhered to.

Key Design Criteria

BASEPLATE
BASEPLATE

This information is designed is to help you select a stanchion / handrail system that

Lionweld Kennedy Standard Sizes

is compliant with the British Standard – BS4592-0:2006 + A1:2012.

To ensure your handrail meets the key design criteria, Lionweld Kennedy offer a
standard design to compliment our steel grating products up to 50mm deep.

The table below shows the tail length and the toe plate size required to ensure

500mm Centres Preferred

the lower opening remains within the 500mm limit and the handrail provides the
minimum 1100mm overall height from the walking surface.

500mm Max
FLAT BASE STANDARD SIZES
Toe Plate Toe Plate
Grating Ball Tail required Upstand required

1100mm Minimum
Depth Centres Length (if welded to Provided (if fixed to
flooring) handrail)
25mm 500mm 650mm 150mm 125mm 100mm

30mm 500mm 650mm 150mm 120mm 100mm

500mm Max
40mm 500mm 650mm 150mm 110mm 100mm

Tail Length
50mm 500mm 650mm 150mm 100mm 100mm

Toe Plate (100mm Min.)

SIDE PALM STANDARD SIZES
Toe Plate Toe Plate
Grating Ball Tail required Upstand required
Depth Centres Length (if welded to Provided (if fixed to
flooring) handrail)
25mm 500mm 725mm 150mm 125mm 100mm 20mm Max
GRTG Depth
30mm 500mm 725mm 150mm 120mm 100mm

40mm 500mm 725mm 150mm 110mm 100mm

50mm 500mm 725mm 150mm 100mm 100mm

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STANCHIONS BASE PLATES
Tubular Stanchion Sizes Standard Base Plates
All stanchions are manufactured using S235JR grade material with a
3.0mm wall thickness.

Other sizes are available upon request. Ball

BALL SIZE
STANCHION SIZE RAIL SIZE
(NOMINAL DIAMETER)

Ball Centres
25nb (33.7mm o/d) 60mm 25nb (33.7mm o/d) Shank
Type D Flat Base Type A Side Palm Type NX Raked
32nb (42.4mm o/d) 60mm 25nb (33.7mm o/d)
Flat Base
32nb (42.4mm o/d) 75mm 32nb (42.4mm o/d)

TAIL LENGH (VARIABLE)

40nb (48.3mm o/d) 75mm 32nb (42.4mm o/d)
Ball

TAIL LENGH (VARIABLE)

150mm
40nb (48.3mm o/d) 75mm 40nb (48.3mm o/d) Type D Top Available Ball Centres Available Toe Plate
Ball Mounted m

Tail Length (variable)

450mm (Typically
25
m

m
100x5

Solid Stanchion Sizes

m
S.O.P for stairs)

65
DATUM m
m
90

=
Shank 500mm 130x5
m
m

Ball Centres
100mm 50
m 533mm 150x5
Shank m
25
Solid stanchions are manufactured using S275JR grade material as

=
Type NX180x5

65mm
m
0m
standard. 19

=
DATUM Type D Fabricated from 6m lengths
Base Plate

BALL SIZE
STANCHION SIZE RAIL SIZE Ball
(NOMINAL DIAMETER)
Ball Type A Available Ball Centres Available Toe Plate
32mm 63mm 25nb (33.7mm o/d)
Side Palm 450mm (Typically
38mm

Tail Length (variable)

70mm 25nb (33.7mm o/d) 100x5
for stairs)

=
65mm

25mm
38mm 70mm 32nb (42.4mm o/d) 500mm 130x5

=
Shank

Ball Centres
100mm
45mm 80mm 32nb (42.4mm o/d) Shank
150mm 533mm 150x5
45mm 80mm 40nb (48.3mm o/d) Type A 180x5

TAIL LENGH (VARIABLE)

Fabricated from 6m lengths
Base Plate DATUM

Bespoke Stanchions
Ball

TAIL LENGH (VARIABLE)

18mm dia hole 150mm

Type NX Top Available Ball Centres Available Toe Plate

Mounted
m

Tail Length (variable)

m
Handrail stanchions can be manufactured with many variations 25

m
m
S.O.P

65
DATUM m 450mm (Typically
m 100x5
including single ball stanchions or three-ball stanchions and can be 90 for stairs)

=
Shank
m
0m
manufactured with special base plates. Where necessary, gate hinges 100mm
m
m
5 500mm 130x5
25
and toe plate brackets can be welded to the stanchions.

=
533mm 150x5
Type NX

65mm
m
0m
19

=
180x5
DATUM Type D
Lionweld Kennedy offer a fully bespoke fabrication service for industrial Base Plate
Fabricated from 6m lengths
handrailing to suit simple or high complexity designs.

Heavy Duty Base Plates

We are able to manufacture handrailing for walkways, staircases and
storage tanks whilst also allowing for non-standard connections such as
welded joints. All fabricated handrail is drawn using our CAD or Tekla
software then fabricated and piece marked for easy on site erection.

Saferail is supplied as pre-galvanised tube as standard but is also available

with a hot dipped galvanized or self colour finish.

GX Base Plate Type FX Base Plate

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MODULAR HANDRAIL CONNECTORS & FIXINGS
BENDS K25 / K40 CONNECTOR
K25 Used with:
Pre-fabricated handrail sections are held in stock to facilitate speedy • 25nb Tubular Stanchions
deliveries, allowing simple handrail systems to be formed without • 32mm dia. Solid Stanchion
the need for bending on site.
K40 Used with:
• 32nb Tubular Stanchions
• 40nb Tubular Stanchions
• 38mm dia. Solid Stanchion

TOE PLATE CONNECTORS

To accompany the KickKlamps, corner brackets (KCB1 / KCB2) and straight connectors
(KCB3) can be used to join the lengths of toe plate as required.

Ramp Bend 90 Degree Bend

KCB1 KCB2 KCB3

Internal Connector External Connector Straight Connector

HANDRAIL CONNECTORS
EXPANDING CONNECTORS DOWEL CONNECTORS
Expanding handrail connectors are used Each section of handrail tube is drilled
Stair Return Platform Return for joining tubular handrailing: and tapped to enable an M8 grub screw
to be located between the groove of the
• 25mm nominal bore (33.7mm o/d), connector and be secured into position.
• 32mm nominal bore (42.4mm o/d), This type of connection is generally used
• 40mm nominal bore (48.4mm o/d) for 3.2mm thick handrail.

The handrail connectors are simply 2 No M8 G-Screws -

40mm
40mm
pushed into the tube and secured by Ends of rail drilled and
tapped to suit
tightening the grub screw with an Allen
key. This type of connection is generally
used for handrail with a 3.2mm wall
thickness.
LK Solid Dowel Joint Type 1 - Solid
Connector Dowel Connector

mm
20
Wreath Bend 6.4m Straight Length 80
mm

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TOE PLATE / KICKKLAMP HANDRAIL LOAD TABLES
Toe plate is used to form a barrier to prevent objects falling off the TOP MOUNTED - 1150mm HIGH STANCHIONS (TWO HOLE FLAT BASE)
edge of the walkway. 5mm flat bar is supplied in various heights Max Centres of
Tubular Stanchion Shank Material Loading Ball Baseplates Handrail Section
(depending on the depth of flooring) to provide a 100mm high edge Shank Size Grade Category
1150mm High
Diameter Thickness Size
Stanchions
protection around the open grid flooring.
33.7mm o/d x 3.0mm 33.7mm o/d x 3.2mm
S235 0.36kN/m 750mm 64mm 12mm
Wall Thickness (25nb) Wall Thickness (25nb)
Toe plate can be either welded to the flooring or attached to the
33.7mm o/d x 3.2mm
handrail stanchions using a U bolt or our innovative KickKlamp system. 42.4mm o/d x 3.0mm
64mm 12mm
Wall Thickness (25nb)
S235 0.36kN/m 1250mm
Wall Thickness (32nb) 42.4mm o/d x 3.2mm
64mm 12mm
Wall Thickness (32nb)
33.7mm o/d x 3.2mm
48.3mm o/d x 3.0mm Wall Thickness (25nb)

KICKKLAMP SYSTEM
S235 0.36kN/m 1660mm 75mm 15mm
Wall Thickness (40nb) 42.4mm o/d x 3.2mm
Wall Thickness (32nb)
42.4mm o/d x 3.2mm
48.3mm o/d x 5.0mm Wall Thickness (32nb)
S355 0.74kN/m 1050mm 75mm 15mm
Wall Thickness (40nb) 48.3mm o/d x 3.2mm
KickKlamp brackets (K25/K40) are a revolutionary system for fixing kick Wall Thickness (40nb)
flat / toe plate to handrail standards. 33.7mm o/d x 3.2mm
32mm Diameter Solid S275 0.36kN/m 1380mm 60mm 12mm
Wall Thickness (25nb)
The basic principle involves gripping the toe plate with steel ‘forked 0.36kN/m 1720mm 70mm 15mm
33.7mm o/d x 3.2mm
Wall Thickness (25nb)
fingers’ and fixing to the stanchion with a single grub screw. 38mm Diameter Solid S275
42.4mm o/d x 3.2mm
0.74kN/m 1120mm 70mm 15mm
Wall Thickness (32nb)

SIDE MOUNTED - 1225mm HIGH STANCHIONS (TWO HOLE HORIZONTAL SIDE PALM)

GATES Tubular Stanchion

Shank Size
Shank Material
Grade
Loading
Category
Max Centres of
1225mm High
Stanchions
Ball
Diameter
Baseplates
Thickness
Handrail Section
Size

33.7mm o/d x 3.0mm 33.7mm o/d x 3.2mm

Self closing gates are designed to compliment our handrail system Wall Thickness (25nb)
S235 0.36kN/m 700mm 64mm 12mm
Wall Thickness (25nb)
and are usually provided with an enclosed spring assembly, hinged to 33.7mm o/d x 3.2mm
64mm 12mm
an adjoining handrail stanchion or bolted to a flat member, such as an 42.4mm o/d x 3.0mm Wall Thickness (25nb)
S235 0.36kN/m 1170mm
Wall Thickness (32nb) 42.4mm o/d x 3.2mm
angle, using a 65mm x 850mm x 12mm thick fixing plate. 75mm 12mm
Wall Thickness (32nb)
33.7mm o/d x 3.2mm
BS4592-0:2006+A1:2012 requires gates to 48.3mm o/d x 3.0mm Wall Thickness (25nb)
S235 0.36kN/m 1570mm 75mm 15mm
provide equal protection to that required Wall Thickness (40nb) 42.4mm o/d x 3.2mm
for the surrounding guarding. Wall Thickness (32nb)
42.4mm o/d x 3.2mm
It should consist of a handrail, at least 48.3mm o/d x 5.0mm Wall Thickness (32nb)
one intermediate or knee rail and a toe S355 0.74kN/m 1010mm 75mm 15mm
Wall Thickness (40nb) 48.3mm o/d x 3.2mm
plate. Wall Thickness (40nb)
33.7mm o/d x 3.2mm
This design criteria makes the traditional 32mm Diameter Solid S275 0.36kN/m 1200mm 60mm 12mm
Wall Thickness (25nb)
half height gate non-compliant unless it
33.7mm o/d x 3.2mm
is being used at ground level where toe 0.36kN/m 1720mm 70mm 15mm
Wall Thickness (25nb)
plate is not required. 38mm Diameter Solid S275
42.4mm o/d x 3.2mm
0.74kN/m 1010mm 70mm 15mm
Wall Thickness (32nb)

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 Lionweld Kennedy Flooring Ltd
Marsh Road
Middlesbrough
TS1 5JS

Reception: +44 (0) 1642 245151

Sales: +44 (0) 1642 233299
Technical: +44 (0) 1642 233297
Email: [email protected]

Due to our policy of continual improvement we

reserve the right to change specifications at all
times without prior notice.

November 2023 LK-UK.COM