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“Ensuring safety in industrial environments is a top priority and railing systems play a crucial role in this. But Is Traditional welded railing systems still the best option? Enter modular railing systems – an innovative, efficient, less time consuming and cost-effective solution that is rapidly replacing welded handrails across multiple industries.”
Handrail systems play a crucial role in ensuring safety, serving as essential barriers that protect individuals from potential hazards in various industrial environments. Beyond their architectural appeals, railings are vital safety components designed to prevent falls and facilitate safe access in multiple industrial environments. While traditional welding systems are effective, their installation can be too costly and time consuming. This is where modular railing systems presents a significant advantage offering a more efficient, cost effective. The system not only minimizes the time, money and also minimal disruption to interior spaces during installation, making them first choice in modern safety solutions.
Choosing a railing system can feel overwhelming with so many options. A well-known choice, trusted by many, is steel railings. They not only offer strength and durability but also bring a sleek and modern look. In this guide, we'll delve into the two types of steel railings: welded railings and Modular Railings. Knowing these differences can help you pick the right one for your project.
Welded Railings: A Traditional Approach
Welded railings have been used in construction for quite some time. This method involves welding different parts, like pipes, elbows, and bottom flanges, together. Usually, these pieces are cut to size on-site before welding. Sometimes, pipes and plates are bent to form joints (which are then welded) without using pre-made parts. This method is labor-intensive and requires a skilled welder to ensure the joints are strong and look good.
The Process of Welded Railings
Creating welded railings starts with picking suitable materials. Steel is often chosen due to its resistance to corrosion and strength. Then, the materials are cut to desired lengths and shapes—a crucial step since any mistakes can cause problems during welding.
Once cut, the pieces are brought to the site for assembly and welding. Welding demands precision & skill since the entire railing’s strength depends on good welds. Poor welding can create weak points in the railing (making it unsafe). Also, welding may leave marks that need extra work to appear polished & smooth
On the other hand, modular railings provide a more modern and simple approach to building railings. This system uses pre-made fittings and components designed for on-site assembly without welding. Unlike having pipes cut on-site, they are cut to size in a factory, ensuring precision and reducing mistakes during installation.
The Process of Modular Railings
Making modular railings begins with prefabricating components like elbows, connectors, and base plates to exact specs. Then, pipes are cut according to the required lengths and readied for assembly.
A significant plus for modular railings is their fastening system. Instead of welding, components are connected using mechanical fasteners such as allen key. This facilitates quick & easy installation since everything fits perfectly together.
Another significant benefit is flexibility. The pre-made joints adapt to minor imperfections in site construction, making it much easier to achieve a perfect fit. This flexibility helps immensely in projects where maintaining precise measurements could be tricky.
Common Issues of Fabricated Handrails:
Traditional welding has been preferred for years but faces several challenges that are listed below: -
Why Should You Use Modular Handrails Over Fabricated Handrails?
When it comes down to handrail solutions—choosing between modular/fabricated may seem daunting! Modular handrails consist of prefabricated components easily assembled together, including fittings/connectors/tubing rails typically made from steel/aluminium:
Modular Railing offers easy assembly without welding, whereas fabricated handrails constructed by welding steel tubes/bars forming rigid structures may appear cost-effective yet pose significant risks/drawbacks experts should be aware of.
Modular railing offers a cost-effective alternative to traditional welding methods. Minimizing labor costs, speeding up project completion, reducing material waste & simplifying repairs make modular systems the best choice without sacrificing valuable project time or budget.
Benefits of Modular Railing System:
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Modular railing represents future-ready solutions combining cost-efficiency and whilst ensuring the utmost safety standards!!
Kee Klamp offers versatile solutions designed to fit standard sizes of structural steel tubes, meeting stringent safety standards. Its exceptional durability and flexibility ensure reliable protection for users in various environments. It is backed by a commitment to compliance, quality, and customer satisfaction globally!!
Major Difference:
Pipe railing constructed using Kee Klamp fittings feature are as follows:
Case Study :
A large manufacturing facility from India chose Kee Klamp handrails over welded railings due to several challenges mentioned below:
Heavy machinery presence led to frequent corrosion issues in weld shops despite regular maintenance efforts. Painting or rust treatments often deteriorate quickly, causing safety concerns and increasing downtime.
Fixed welded railings obstructed changes, requiring the welding team to cut or re-weld sections, delaying productions, causing additional labour costs, hindering layout optimization, and maximizing efficiency. The Swift market demands adaptations!
Meeting OSHA standards for specific height, load bearing and fall-protection involves time consuming retrofitting and replacements. This process risked fines from regulatory authorities and posed serious safety hazards for workers.
Kee Safety India's Implementation reduced maintenance requirements, resulting in significant cost savings and operational efficiency. The solution facilitates swift adaptability, ensured compliance with regulations, and provided proper documentation, including maintenance procedures and certifications, making regulatory processes easier and risk-free.
Kee Safety India provided customised modular safety railing solutions by thoroughly accessing the facility needs and creating tailored solutions. Also ensured compliance with strict safety regulations, making the entire process simple and cost effective while avoiding complex issues related to regulatory requirements.
Because of Kee Safety India’s impact of modular railings, the transition from welded handrails to Kee Klamp Modular systems was smooth, also the result was 40% reduction in maintenance cost and significant improvement in safety standards of the manufacturing facility.
A significant plus for Kee Klamp modular railings is their fastening system. Instead of welding, components are connected using mechanical fasteners such as allen key. This facilitates quick & easy installation since everything fits perfectly together. Find out more about Kee Klamp ® Galvanised Railings
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