On a busy site, safety measures around stairs, walkways and platforms need to protect people from falls, changes in level and other nearby hazards.

Tubular handrails can be a practical option in these situations, particularly where a system needs to be configured around an existing layout or adapted in the future.

They can also form part of a wider site safety setup alongside Armco barriers, which are more commonly used where vehicle impact is a risk.

In this guide, we’ll look at where tubular handrails can be used, the benefits of a galvanised system and how they can be used alongside Armco barriers.

What is a tubular handrail system?

Tubular handrail systems use galvanised steel tubing and slip-on fittings to create a fixed safety handrail or pedestrian barrier. The fittings are secured around the tube without welding, making the system straightforward to assemble and modify.

This modular construction gives you more flexibility when installing protection around existing stairs, walkways, platforms, machinery and other site features. Sections can also be altered or extended where the layout needs to change.

When should you use tubular handrails?

Tubular handrails are best suited to areas where you need to create a physical boundary, guide pedestrian movement or provide guarding around an access area.

Common applications include:

Stairs: Providing support and helping to keep pedestrian access routes clearly defined.
Walkways: Creating a defined pedestrian route through a warehouse, factory or other working environment.
Platforms: Providing edge protection around raised platforms and access areas.
Industrial access areas: Particularly where people need to move around machinery, equipment or other workplace hazards.
Uneven or changing layouts: Where the system needs to accommodate existing site features or may need to be altered as the layout changes.

For example, a pedestrian walkway alongside a loading area may require a physical barrier to separate employees from nearby work areas. Tubular handrails can provide that separation without creating a permanent barrier around the entire area.

The modular system can also be used where the layout needs to accommodate corners, access points or other site features, or where the configuration may need to be altered later.

What are the key benefits of galvanised tubular handrails?

A key advantage of tubular handrails is their modular construction.

The components use slip-on fittings rather than requiring each joint to be welded, which can make installation quicker and allow the system to be dismantled or reconfigured more easily than a permanently welded structure.

That can be useful in industrial environments where layouts change over time. A walkway, access route or piece of equipment may move, creating a need to alter the surrounding guarding. The system can also be used across a range of environments, rather than being limited to one type of application.

The galvanised steel finish makes tubular handrails suitable for both indoor and outdoor use, providing protection against corrosion where the handrails are exposed to moisture and outdoor conditions. This could include pedestrian routes within a warehouse as well as external access areas, stairways and platforms.

Galvanised steel is also durable and relatively low maintenance, making it well suited to industrial environments.

The flexibility comes from the way the system is designed and assembled, rather than from the handrail being suitable for every type of hazard. Any existing components should still be assessed for their condition and suitability before being reused or reconfigured.

Tubular handrails and Armco barriers

Although both systems can be used as part of a wider approach to site safety, tubular handrails and Armco barriers have different primary applications.

Decision point	Tubular handrails	Armco barriers
Primary role	Guarding, access support and defining pedestrian routes or boundaries	Vehicle-impact protection for people, structures, equipment and site assets
Typical locations	Stairways, walkways, platforms and industrial access areas	Warehouses, factories, car parks, loading areas, service yards and vehicle routes
Impact risk	Not a crash barrier	Designed to provide protection against vehicle impact
Flexibility	Modular construction can make assembly and reconfiguration easier	Configurable through different beam, post, corner and terminal arrangements

Consider a warehouse where a pedestrian walkway runs alongside a forklift route. Tubular handrails may be suitable for defining the pedestrian route, while Armco barriers could provide protection where there is a risk of vehicle impact.

The two systems are not interchangeable. Different sites will have different safety requirements, and the most suitable safety measures will depend on individual circumstances.

Can tubular handrails and Armco barriers be used together?

Yes. A site may need different types of protection in different areas, particularly where pedestrian and vehicle movements take place alongside one another.

For example, tubular handrails could be used to define a pedestrian walkway running through a warehouse, while Armco barriers provide impact protection around loading areas or other locations where vehicles are operating.

A combined approach, using both tubular handrails and Armco barriers, can therefore help to address different risks rather than expecting one type of system to perform every function.

The key is to consider the specific hazards in each area and select a safety system that provides the appropriate type of protection.

Choosing the right protection for your site

Tubular handrails are a practical option where the priority is pedestrian safety around stairs, walkways and platforms. Their modular construction makes them straightforward to install and adapt where requirements change.

Where vehicles or machinery create an impact risk, Armco barriers are a more appropriate safety solution. In some areas, a combination of both may be appropriate where pedestrian safety and vehicle-impact protection are required.

If you’re planning a new safety barrier installation or reviewing existing protection, consider the hazards present, how people and vehicles move through the area and what each safety measure needs to achieve.

For areas where vehicle impact is the concern, explore the Armco barrier range and use our Armco Barrier Calculator to help determine the requirements for your project.

Call us on (01977) 666 818 or send an email to sales@ctsafetybarriers.co.uk.