Sharp edge of handrail 2

[jasem81]

What are the best solutions to solve the issue of sharp edge shown in the below photos
We have huge quantity and client didnt accept the current status

 

[TehMightyEngineer]

Grinder? A thick epoxy coating of some sort? Gloves?

Professional Engineer (ME, NH, MA) Structural Engineer (IL)
American Concrete Industries

https://www.facebook.com/AmericanConcrete/

 

[dik]

I can't tell from the photo, but, is it the roughness of the galvanising? Gloves are not a solution. The surface may be carefully ground off, but, may cause a greater problem. How corrosive is the environment? A high build zinc rich epoxy patch smoothing out the roughness in conjunction with local grinding may work. This may cause cosmetic problems; it will not oxidize like normal HDG. You should review your 'dipping' procedure. We used to give the object a sharp smack with a hammer when it emerged from the tank (I worked in a galvanising shop for a couple of summers while going to university). This tended to leave a smooth surface.

Dik

 

[JStephen]

Send it back to the galvanizers? (Redip it upright?)
Sand it smooth and paint the handrail "safety yellow"?
Get a copy of the galvanizing spec and see if it says anything about the topic?
Ask the galvanizers about it?

 

[JLNJ]

Paint (especially oil-based) and galvanized metal don't play well together. Be careful about surface prep and material choice.

 

[dik]

As JLNJ notes, the coating should be compatible with zinc. Many coatings in particular oil based, form a zinc saponification that over a short period of time causes the bond to fail. Check with your coating supplier to get a coating that works.

Dik

 

[jimstructures]

Could the Original Poster mark up the attached photograph with arrows pointing at the mystery sharp edge???

Jim

 

[jasem81]

new photo,
implementing coating seems good idea,can any one help and give me the material name please

 

[Tmoose]

"sharp edge" and the two pics provided still leave me scratching my head as to what is unacceptable.

 

[jasem81]

Tmoose,
You are right, the problem that Client is not accepting the current status and he is considering this shape is not meeting the HSE requirements, we have huge quantity which is already erected, we need to find a solution away from cutting and welding

 

[dik]

A couple of coating systems:

SYSTEM 10: EPOXY COATING OVER HDG
BASE METAL -HDG STEEL
CLEANING -TO SSPC-SP 1
WASH -POLYCLUTCH 97-687 BY PPG
PRIMER -AMERLOCK 400 TWO COMPONENT EPOXY BY PPG
TOPCOAT -AMERCOAT 450H TWO COMPONENT ALIPHATIC POLYURETHANE TOPCOAT BY PPG

SYSTEM 11: EPOXY COATING OVER HDG (ALTERNATIVE)
BASE METAL -HDG STEEL
CLEANING -TO SSPC-SP 1
PRIMER -DEVOE DEVRAN 201 EPOXY
TOPCOAT -DEVOE DEVTHANE 379 URETHANE

The topcoat can be safety yellow... What HSE requirements and why is it not conforming?

Dik

 

[dhengr]

Jasem81:
You’re not doing a very good job of explaining to us or showing in your photos, exactly what the various problems are. You should get with your customer and actually list the various types of roughness and sharp spots, and approx. quantities, etc., so you have an idea of what tools will be used most and are most important. The customer has every right to be concerned about these problems on handrails and the like, when his workers are going to cut their hands when using the handrails.

It looks like you have one size of pipe handrail, and then maybe several different roughness problems on them. I would be looking for some tools and light machines which semi-skilled workers could use on every handrail assembly on the project to clean these rough and sharp spots up. The single size pipe should simplify you tooling needs. Auto body shops have some shaping and finishing tools for non-flat surfaces which might work for some of the problems. Maybe some woodworking or light machine shop tools like belt sanders, flap sanding wheels, angle grinders, various other grinders, routers, etc. might work. The trick is to mount these to shaped bases, matching the pipe dia. so the workers can’t do more damage than they do good. Maybe a special shaped cutter/grinder and tool base will slide along, right on the pipe shape, and just clean up the high spots. This all takes some imagination and engineering judgement on your end. Certainly, I would involve your other subs who played a part in this mess.

 

[rb1957]

it looks to me as though the issue is the support structure near the hand rail. the hand rail is welded to what looks like an angle section which is close to the hand rail, interfering (maybe?) with someone grabbing at the hand rail. doesn't look particularly sharp (looks rounded), I guess the upright supporting the hand rail is an angle, with a flange welded to the stairs ?

did the client accept the drawings before assembly ? (I'm guessing not)

I'm guessing that maybe the hand rail should have been welded to the offending flange ?

another day in paradise, or is paradise one day closer ?

 

[TehMightyEngineer]

rb1957 has it I think. I thought OP was talking about roughness of the rail itself but his 2nd picture seems to show the supporting angle as being the issue. Completely different problem, please explain this better next time OP.

We always use pipes the same size as the rail to avoid this issue. Just want to be clear; is this a handrail or a guardrail (fall protection). There's a big difference.

Professional Engineer (ME, NH, MA) Structural Engineer (IL)
American Concrete Industries

https://www.facebook.com/AmericanConcrete/

 

[BAretired]

Handrails should be smooth. The handrail in the first photo looks rough and needs to be ground and rubbed smooth in order to gain acceptance.

The handrail in the second photo appears smooth; I'm not sure what the problem is with it.

BA

 

[dik]

BART: Can a finger get caught between the rail and the vertical?

Dik

 

[kingnero]

If the parallel edge of the angle is on the "inside to the stairs" side (instead of on the outside), I'd refuse it as well:
If someone were to fall of the stairs and bashed their heads on that edge, it could possibly cost them their life.

Reweld the angle so that the parallel edge is underneath the hand rail, and the perpendicular (to the handrail) side points outwards. Better still, choose pipe for the posts.

http://www.fusionpoint.be

http://be.linkedin.com/in/fusionpoint

 

[Tmoose]

Hi Jasem81,

The conclusion you should draw from all the posts is - no one is at all sure what the "problem" is.
regards,

Dan T

 

[Hokie93]

What building code are you following? The angle member shown in the second photograph does not appear to meet the requirements of IBC 2012 Section 1012 (Handrails), specifically with regard to clearance requirements around the handrail itself. Further, is this a guardrail or a handrail?