When it comes to handrail solutions, choosing between modular handrails and fabricated handrails may seem like a daunting task. Modular handrails are a type of handrail system that consists of prefabricated components designed to be easily assembled-together. These components typically include fittings, connectors, and tubing or rails made from materials such as steel or aluminium. Modular handrails offer a system of components that can be easily assembled without welding or fabrication, whereas fabricated handrails are constructed by welding steel tubes or bars together to form a rigid structure.
While fabricated handrails may appear to be a more cost-effective option, they pose significant risks and drawbacks that experts should be aware of. In this article, we will delve into the technical details of why modular handrails are a superior choice over fabricated handrails. We will explore how modular handrails can save you time, money, and hassle in the long run by eliminating the need for welding or fabrication and offering superior durability and strength.
Why Not to Use Fabricated Handrails?
Fabricated handrails may look sturdy and strong, but they are prone to many types of welding defects that can compromise their quality and safety. Welding defects are flaws, irregularities, and imperfections that weaken the joint and affect the intended function or appearance of the weld. Some of the common welding defects are:
Cracks: These are fractures or separations in the weld metal that can cause the handrail to break or collapse. Cracks can occur due to various causes, such as thermal stress, hydrogen embrittlement, improper cooling, or poor weld design.
Porosity: These are small holes or cavities in the weld metal that reduce its strength and corrosion resistance. Porosity can occur due to trapped gas, moisture, or contaminants in the weld pool or the base metal.
Lack of fusion: This is when the weld metal does not fully bond with the base metal, leaving gaps or voids in the joint. Lack of fusion can occur due to insufficient heat, improper fit-up, or incorrect welding technique.
Incomplete penetration: This is when the weld metal does not fill the entire depth of the joint, leaving a weak or thin section. Incomplete penetration can occur due to low current, high travel speed, or improper joint preparation.
Undercut: This is when the weld metal melts away the edge of the base metal, creating a groove or notch along the weld toe. Undercuts can occur due to excessive current, high travel speed, or an incorrect electrode angle.
Spatter: These are small droplets of molten metal that are ejected from the weld pool and stick to the surface of the base metal or the adjacent welds. Spatter can occur due to high current, arc instability, or improper shielding gas.
These welding defects can affect not only the structural integrity but also the aesthetics of the fabricated handrails. They can also lead to corrosion, fatigue, or stress cracking over time, resulting in premature failure or costly repairs. Moreover, welding defects can cause the fabricated handrails to fail inspection or rejection, wasting your time and money.
Fittings vs Fabrication
Why Should You Buy Kee Klamp?
Why Should You Buy Kee Klamp?
The best Choice for Modular Handrails is Kee Klamp from Kee Safety. Kee Safety, a leading provider of safety solutions worldwide, offers the versatile Kee Klamp modular handrail system, designed to fit standard sizes of structural steel tubes that meet stringent safety standards while providing exceptional durability and flexibility. With its galvanized steel fittings and tubing that is corrosion-resistant, Kee Klamp allows for easy assembly without the need for welding or specialized tools, making it suitable for a wide range of applications including staircases, ramps, walkways, and platforms. The modular nature of Kee Klamp enables customized configurations tailored to specific layouts and requirements, ensuring reliable protection for users in various environments. Backed by Kee Safety's commitment to compliance, quality, and customer satisfaction, Kee Klamp stands as a trusted choice for safety handrail solutions globally.
Kee Klamp has many advantages over fabricated handrails, such as:
No welding defects: Kee Klamp eliminates the risk of welding defects, as there is no welding involved in the assembly process. All you need is a hex key to tighten the set screws that secure the fittings to the tubes. This ensures a strong and consistent connection that lasts for years.
Easy to adapt: Kee Klamp is flexible and versatile, as you can adjust, modify, or extend your handrails as needed. You can also choose from a variety of finishes, such as galvanized steel, aluminum, or powder-coated colors, to match your style and environment. You can also add accessories, such as toeboards, infill panels, or safety gates, to enhance the functionality and safety of your handrails.
Easy to install and repair: Kee Klamp is simple and quick to install, as you don’t need any special tools or skills to assemble your handrails. You can also save on labor and material costs, as you don’t need to hire a welder or buy welding equipment and consumables. If you need to repair or replace a damaged section, you can simply remove and replace the fittings and tubes, without affecting the rest of the handrail.
Compliant: Kee Klamp meets or exceeds the international safety standards for handrails, such as EN and OSHA. You can be assured that your handrails are safe and secure, and pass the inspection and approval process.
It lasts up to seven (7) times longer than fabricated railing.
It can easily be repaired if it is damaged.
It does not pose the same health and safety risks as building fabricated railing.
It can be installed by a standard labourer, reducing the dependence on specialized labourers.
Case Study
A reputed industry player choosing Kee Klamp over welded railings is the case of a large manufacturing facility from Indonesia that needed to upgrade their safety railings.
Problem Statement:
The manufacturing facility faced several challenges with its existing welded railings:
Maintenance Issues: The presence of heavy machinery in the manufacturing plant faced frequent corrosion issues with their welded steel railings due to exposure to harsh chemicals and industrial environments. Despite regular maintenance efforts, including painting and rust treatment, the railings often deteriorated quickly, leading to safety concerns. This resulted in increased downtime as sections of the railing needed to be cordoned off for repair, affecting production schedules and efficiency.
Lack of Flexibility: The Manufacturing plant has an assembly section where often reconfigured its production lines to accommodate new models or process improvements. However, the fixed welded railings along the assembly lines obstructed these changes. Each time a modification was required, the welding team had to be called in to cut and re-weld sections of the railing, causing delays in production and additional labour costs. The lack of flexibility hindered the plant's ability to optimize its layout for maximum efficiency and adapt to market demands swiftly.
Regulatory Compliance Challenges: The manufacturing unit of heavy machinery had stringent safety regulations to adhere to, including OSHA (Occupational Safety and Health Administration) standards. However, their welded railings did not meet the specific height and load-bearing requirements for fall protection in certain areas of the facility. Achieving compliance involved retrofitting the railings with additional welded components or installing entirely new sections, which proved to be a time-consuming and costly process. Non-compliance risked fines from regulatory authorities and posed a serious safety hazard to workers.
Proposal by Kee Safety:
Kee Safety proposed the implementation of Kee Klamp modular railing systems to address the challenges faced by the manufacturing facility. Kee Klamp comes with corrosion-resistant galvanized steel/aluminium fittings, a modular design for easy assembly/disassembly without welding, and compliance with safety standards for seamless integration.
Proposal Implemented in the Facility:
Assessment and Planning: Kee Safety conducted a thorough assessment of the manufacturing facility's safety railing needs, considering factors such as layout, usage patterns, and regulatory requirements.
Customization: Based on the assessment, Kee Safety customized the Kee Klamp modular railing system to meet the specific requirements of the facility, including railing height, configuration, and material specifications.
Installation: Trained professionals from Kee Safety installed the Kee Klamp railing system according to the facility's layout and safety standards. The modular nature of Kee Klamp facilitated swift and efficient installation without the need for welding or extensive on-site fabrication.
Training: Kee Safety provided training to facility personnel & Safety Manager on the assembly, disassembly, and maintenance of the Kee Klamp railing system to ensure proper handling and compliance with safety protocols.
Testing and Inspection: After installation, the Kee Klamp railing system underwent rigorous testing and inspection to ensure compliance with safety regulations and standards.
Documentation: Kee Safety provided comprehensive documentation, including installation guides, maintenance procedures, and compliance certifications, to assist the facility in ongoing maintenance and regulatory compliance efforts.
Results and Outcomes:
Cost Savings: The reduced maintenance requirements and longevity of Kee Klamp railings resulted in significant cost savings over time, minimizing downtime and maintenance expenses.
Operational Efficiency: The flexibility of Kee Klamp allowed the facility to adapt to changing needs swiftly, optimizing workflow and operational efficiency.
Regulatory Compliance: Kee Klamp's compliance with safety regulations simplified the facility's compliance efforts, ensuring adherence to standards without additional complexities or costs.
As you can see, Kee Klamp is a superior choice over fabricated handrails, as it offers more benefits and fewer drawbacks. Kee Klamp is a proven and trusted system that has been used for over 80 years in various applications and industries, such as agriculture, construction, manufacturing, and transportation. Whether you need handrails for your stairs, platforms, mezzanines, walkways, or bridges, Kee Klamp can provide you with a reliable and durable solution that meets your needs and expectations.
Contact Us
If you are interested in buying Kee Klamp or learning more about its features and applications, please visit our website or contact us today.
We are happy to assist you with any questions or inquiries you may have. Thank you for reading this post, and we hope you found it informative and helpful.
