Ezi Klamp Systems — Technical Guide
GRP Handrail
Installation
Guide
Use this guide to learn how to assemble GRP handrails in various situations. GRP handrails offer ultimate protection in dangerous zones and can be configured in many ways to meet your requirements.
Before You Start
Standard Principles
Key measurements and requirements to follow when planning and installing your GRP handrail system.
Post Spacing
To comply with 0.74KN loading requirements, GRP handrail posts should be spaced at 1000mm centres maximum. 1250mm post spacing can be done, but will not meet this loading requirement.
Handrail Height
GRP handrails are recommended to be minimum:
1100mm high on a level surface.
900mm high on a ramp or steps.
1250mm high when used for edge protection.
Mid-Rail Height
On standard double rail GRP handrails, the middle rail shouldn’t be more than 550mm down from top rail, centre to centre. Space between rails = 500mm.
Bolt Down Fixing
When fixing with baseplates, ensure there is at least 30mm clearance from the edge of the baseplate to the edge of the surface you are fixing onto.
Handrail Width
GRP tubes are 50mm diameter. If you are fixing with baseplates, ensure the surface you are fixing to is at least 170mm wide to ensure a sturdy handrail.
Fitting Fixings
All 2-part fittings are fastened together with A2 grade stainless steel bolt & rivnut creating a durable handrail system. See assembly instructions below for full details.
System Overview
DDA Handrail Diagram
The diagram below shows all 8 assembly configurations covered in this guide.
Assembly Methods
The Basics
Two fitting assembly methods are used depending on the fitting type.
Two-Piece Fitting Assembly
For all fittings with 2 parts — e.g. GRP-101, GRP-128 fittings.
- 1Firstly clamp fitting parts around the post/tube in the position to be fitted.
- 2Each two-piece fitting has a marked position for the bolt & rivnut. Simply drill a 9mm hole through the fitting parts & tube while it is clamped.
- 3Push the stainless steel rivnut into one side of the fitting, and the bolt into the opposite side. Tighten with a screwdriver or drill on low chuck speed.
One-Piece Fitting Assembly
For baseplate fittings, side mount & swivel fittings — e.g. GRP-166, GRP-173.
- 1Fix the fitting to the fixing surface with bolts in the correct position, or if a swivel fitting, attach with bolt & rivnut.
- 2Now fit the tube into the fitting using one of two methods:
A. PU Glue — apply glue into the fitting, insert tube. Optionally add a tek screw underneath to hold while glue sets.
B. Tek Screws — drill 2–4 TEK screws, 1 each side of fitting to hold tube in place.
Configurations 1–6
Post Assembly Guide
Step-by-step fitting guide for all six post and corner configurations.
Standard Post
All GRP post variants on level surfaces can be bolted down, side mounted or root fixed. GRP-101-4 connects top rail to post. Use GRP-104-4 when joining top rails. GRP-119-4 connects middle rails. Post bolted down with GRP-132-4.
End Post
Used at the end of a handrail run. GRP-125-4 returns the top rail to the post. GRP-101-4 connects the middle rail. Post bolted down with GRP-132-4.
Corner Post
Creates a 90° bend in the handrail run. GRP-128-4 top-rail fitting and GRP-116-4 mid-rail fitting form the 90° bend. Post bolted down with GRP-132-4.
Ramp/Step Standard Post
All ramp/step GRP post variants can be side mounted or root fixed. Use GRP-173-4 swivel for top rail, GRP-167-4 swivel for mid-rail. Post side fixed with GRP-145-4.
Ramp/Step End Post
Used at the end of a ramp/step run. Use GRP-173-4 swivel to return both top and middle rails into the end post. Post usually side fixed with GRP-145-4.
Corner Options
90° offset corner — formed using 2 × GRP-125-4 fittings.
Variable corner — if less or greater than 90°, use 2 × GRP-166-4 fittings.
Diagram A
Triple Rail Set Up
If a third rail is required, insert another rail and use the same fittings as instructed for the middle rail.
The third rail can be added at a height of your choice, but is usually fitted just above the baseplate fitting or around 100mm above the ground/fixing surface.
Configurations 7 & 8
Base Fixing & End Options
Three base fixing methods and four handrail end options to suit different surfaces and installation requirements.
Base Fixing Options (7)
- Bolt down fixing — GRP-132-4 fitting used on level surfaces.
- Side fixing — GRP-145-4 enables bolting to the side of a ramp or step.
- Dig-in fixing — Concrete the post into the ground for a secure fix.
Handrail End Options (8)
- Level looped end — 2 × GRP-125-4 fittings form a looped end.
- Raking looped end — 1 × GRP-166-4 swivel & 1 × GRP-125-4 elbow for steps or steep ramps.
- Wall mount — End handrails at a wall with 2 × GRP-132-4 baseplates.
- End cap — Use 133-4 plastic end caps on tube ends.
Advanced Assembly
Swivel Fitting Assembly
Swivel fittings are used for ramp and step configurations. Follow the specific steps for each fitting type.
GRP-166-4 Swivel Fitting
GRP-167-4 Swivel Fitting
GRP-173-4 Swivel Fitting
Fixings & Tools
Fixing Methods & Tools Required
Screwbolt Fixing
Commonly used to fasten into concrete & timber surfaces.
- Remove all dust from the hole before inserting the fixing for a strong, secure fix.
- Use an impact driver to tighten the screwbolts to ensure base fittings are securely fixed.
- GRP-132-4 baseplates use M10 fixings.
- GRP-145-4 side mount fittings use M8 fixings.
Resin Anchor Fixing
- Studs should be drilled through a mortar joint on the top soldier course to reduce risk of breaking bricks.
- Holes should be at least 250mm deep.
- Always clean the hole to remove all dust before inserting the resin.
Tools Required
- 9mm HSS drill bit or 9mm Glass bit
- Diamond tipped saw to cut GRP tubes (recommended)
- SDS drill if bolting into concrete or brickwork
- Impact driver / Combi drill for tightening bolts & screws
Other Information
- GRP-132-4 baseplates use M10 fixings
- GRP-145-4 side mount fittings use M8 fixings
- Use No. 12 Tek Screws or PU glue for fixing 1-piece fittings to tube
- All swivel fittings are available as separate components