ZeAllgrate FRP Handrail Systems — Complete Specifications
Non-conductive, corrosion-proof FRP guarding
ZeAllgrate handrail systems are built from pultruded tubes and molded fittings — light, non-sparking and immune to rust in chemical and coastal service.
Component set
Top rail, mid rail, knee rail / toe board, posts, base plates, elbow/tee/cross fittings and wall returns.
Standards compliance
Designed to OSHA 29 CFR 1910.23 / 1910.29, ISO 14122-3 and EN ISO 14122; ADA rail heights where applicable.
Non-conductive
FRP is inherently dielectric — no grounding required; safe near live electrical gear and in classified areas.
Profiles, dimensions, materials and function
Round tube is standard; square tube optional. Wall thickness 3 – 5 mm by loading case.
| Component | Profile / Shape | Dimensions (mm) | Material | Weight (kg/m) | Function |
|---|---|---|---|---|---|
| Top Rail | Round tube Ø50 mm (or 50×50 square) | Ø50 × 4 mm wall / 50×50×4 mm | ZeAll ISO / VE / FR pultruded | ≈ 1.6 | Primary guardrail — resists horizontal & vertical loads |
| Mid Rail | Round tube Ø38 mm (or 40×40 square) | Ø38 × 4 mm wall / 40×40×4 mm | ZeAll ISO / VE / FR pultruded | ≈ 1.2 | Intermediate guardrail — prevents fall through |
| Knee Rail / Toe Board | Flat bar 100×6 mm (or 150 mm high) | 100 × 6 mm / 150 × 6 mm | ZeAll pultruded flat bar | ≈ 0.8 | Fall protection for objects rolling off platform |
| Post | Round tube Ø50 mm (or 50×50 square) | Ø50 × 4 mm, height ≈ 1100 mm | ZeAll ISO / VE / FR pultruded | ≈ 1.6 | Vertical structural member transferring rail loads to base |
| Base Plate | Square / round flange | 150 × 150 × 8 mm, 4 × M12 holes | FRP / SS316 / galvanized | ≈ 0.8 | Anchors post to floor or side-wall structure |
| Elbow / Tee / Cross Fittings | Molded FRP connectors | Matching tube ID | FRP (nylon-lined) / SS316 | ≈ 0.2 each | Join rails to posts at corners, T-junctions and splices |
| Wall Return Bracket | Flat bar / tube bracket | 150 mm projection | FRP / SS316 | ≈ 0.3 | Return top rail to wall at openings / ladder access |
OSHA / IBC / ISO requirements vs. FRP system capacity
Loads are not applied concurrently. Capacities shown are typical with an appropriate safety factor.
| Load Type | Requirement (OSHA / ISO) | FRP System Capacity (typical) | Reference |
|---|---|---|---|
| Top rail — horizontal outward | 890 N (200 lbf) concentrated at any point | ≈ 1.3 – 1.8 kN capacity (F.S. ≈ 1.5 – 2.0) | OSHA 1910.29(b) / IBC |
| Top rail — uniform load | 730 N/m (50 lbf/ft) applied in any direction | ≈ 1.1 kN/m capacity (F.S. ≈ 1.5) | OSHA 1910.29(b) / IBC |
| Top rail — vertical downward | 890 N (200 lbf) concentrated | ≈ 1.3 – 1.8 kN capacity | OSHA 1910.29(b) |
| Mid rail | 670 N (150 lbf) concentrated at any point | ≈ 1.0 kN capacity | OSHA 1910.29(b) |
| Toe board | 1.2 kN/m (20 lbf/ft) or 90 N concentrated | FRP 100 mm toe board exceeds | OSHA 1910.29(k) |
| Impact (side-on) | Per local code / company standard | System designed for impact with safety factor | ISO 14122-3 |
Basis: OSHA 29 CFR 1910.29(b) — 200 lbf (890 N) concentrated downward/outward on top rail or 50 lbf/ft (730 N/m) uniform; ISO 14122-3 guarding requirements.
Select spacing by traffic and rail arrangement
Maximum post spacing 1800 mm per OSHA/IBC; reduce for heavy use or dynamic loading.
| Post Spacing (mm) | Rail Configuration | Application |
|---|---|---|
| 1500 mm (standard) | 2-rail (top + mid) with toe board | General industrial platforms, walkways |
| 1200 mm (heavy use) | 3-rail (top + mid + knee) with toe board | High-traffic, congested or process areas |
| 1800 mm (maximum) | 2-rail (top + mid), no toe board | Low-traffic, light pedestrian; OSHA/IBC maximum |
Pultruded tubes and molded fittings
ZeAll ISO (standard)
Isophthalic pultruded tube — general industrial, atmospheric corrosion; safety yellow / gray.
ZeAll VE (corrosive)
Vinyl ester tube — chemical, coastal and offshore service; superior pitting resistance.
ZeAll FR (fire-rated)
Fire-retardant pultruded tube — E84 Class A / low smoke; metro, marine, enclosed spaces.
| Tube wall options | 3 mm (light) · 4 mm (standard) · 5 mm (heavy duty) |
| Fittings | Molded FRP (standard) · nylon-lined (electrical isolation) · stainless SS316 (high-load) |
| Fasteners | SS304 / SS316 bolts and rivets; never galvanized in coastal / chloride service |
| Property | Test Method | Typical Value |
|---|---|---|
| Glass content | Ignition loss | 70% ± 5% by weight |
| Flexural strength, longitudinal | ASTM D790 | ≈ 350 – 450 MPa |
| Flexural modulus, longitudinal | ASTM D790 | ≈ 22,000 – 26,000 MPa |
| Impact resistance (Charpy) | ASTM D6110 | ≈ 150 – 250 kJ/m² |
| Density | ASTM D792 | 1.7 – 1.9 g/cm³ |
| Dielectric strength | ASTM D149 | > 10 kV/mm |
OSHA/ISO-compliant handrail configuration with heights
Top rail 1070 mm (± 75 mm) above walking surface; mid rail ≈ 535 mm; toe board ≥ 100 mm.
Base mounting, spacing, fitting assembly and grounding
Base mounting
Floor-flange base plate bolted to grating/steel (M12 × 4 anchors); side-mount bracket for wall-parallel rails; weldless FRP angle brackets for FRP-to-FRP.
Post spacing
≤ 1800 mm c/c (OSHA max); 1500 mm standard; 1200 mm for heavy use. Two posts minimum per straight section.
Rail cutting & fitting
Cut tubes square with abrasive saw; rout/fit rails into posts, rivet + bond with vinyl ester adhesive.
Torque & grounding
Torque bolts to 25 – 30 N·m. FRP is non-conductive — no grounding bond required (unlike steel rail).
| Standard | Scope | Requirement Covered |
|---|---|---|
| OSHA 29 CFR 1910.23 / 1910.29 | Walking-Working Surfaces; guarding | Top rail 1070 mm ± 75; 200 lbf load; toe board ≥ 100 mm |
| ISO 14122-1 / -2 / -3 | Permanent access machinery; guarding | Guardrail geometry, loads, post spacing |
| EN ISO 14122 (EU) | Permanent access to machinery | Harmonised European guarding requirements |
| IBC (International Building Code) | Building guard & rail loads | 200 lbf concentrated / 50 lbf/ft uniform |
| ADA / ADAAG | Accessibility handrail height | Handrail 865 – 965 mm above stair nosing (where required) |
Load capacities are indicative; project designs must be verified against OSHA 1910.29 / ISO 14122-3 and local code. Contact [email protected] for a handrail bill of materials and layout.
System Component Set
| Component | Standard Material | Function |
|---|---|---|
| Posts | 50 mm square pultruded FRP tube | Vertical load path to base plate |
| Top rail | 42–46 mm pultruded tube | Upper restraint, 200 lbf (0.89 kN) top-rail load |
| Mid rail | Same section as top rail | Intermediate restraint, 50 lbf/ft distributed load |
| Base plates | SS316 fabricated plate | Bolt-down fixing; corrosion-proof in chemical/marine service |
| Fittings & clamps | Molded FRP or SS316 | Rail-to-post connection; no hot work on site |
Load Verification and Compliance
The system is independently load-tested to the OSHA 29 CFR 1910 walking-working surface criteria (200 lbf top-rail concentrated, 50 lbf/ft intermediate distributed) and designed to the dimensional rules of OSHA, IBC and ISO 14122-3: top rail at 42 in (1070 mm), mid rail at half-height, posts spaced to the load chart. Test reports are available from the downloads library; for project compliance, request the report for the exact component combination and spacing you specify.
Applicable Environments
- Chemical plants — corrosion-proof, no paint cycles around aggressive atmospheres.
- Wastewater and marine — SS316 hardware survives the wet, salty, chemical service.
- Electrical zones — non-conductive rail system removes earthing burden; see the electrical insulation guide.
- Hazardous areas — non-sparking construction where ignition control applies.
- Chemical plants — corrosion-proof, no paint cycles around aggressive atmospheres.
- Wastewater and marine — SS316 hardware survives the wet, salty, chemical service.
- Electrical zones — non-conductive rail system removes earthing burden; see the electrical insulation guide.
- Hazardous areas — non-sparking construction where ignition control applies.
Approved by Industry Bodies, Tested to International Standards
Every ZeAllgrate shipment is backed by documented quality systems, marine approvals and independent third-party verification.
ISO 9001:2015
Certified quality management system — since 2004.
DNV & ABS Marine
Marine-grade grating for offshore platforms and vessel decks.
SGS & Intertek
Independent third-party inspection and load testing on request.
OSHA 1910.23
Handrail systems load-tested to US federal requirements.
Material certificates, COA, ASTM test reports and compliance documentation supplied with every order. View certifications →
Need a Handrail Layout & BOM?
Send your platform layout, post spacing and corrosive environment — we return an assembly drawing, component list and resin selection within 24 hours.