Aberfoyle Park High School
Commercial
Livonia St, Hallett Cove SA 5158
Got questions or need assistance with your Industry needs?
Accessible Ramp Handrails and Balustrades – Primary School Project
For this project, our team was engaged to fabricate and install handrails and balustrades for a newly constructed access ramp at a primary school, designed specifically to improve wheelchair and inclusive access. The project was carried out in strict accordance with relevant Australian Standards, National Construction Code (NCC) provisions, and Department of Education guidelines for accessibility in public education facilities.
In line with AS 1428.1:2021 – Design for Access and Mobility, we installed dual-height handrails to ensure accessibility for both adult users and young students. The lower rail was positioned at 700 mm above the finished ramp surface, while the upper rail was installed at 900 mm, providing appropriate support for users in mobility devices and carers. Both rails featured a continuous gripping surface with a diameter of 42 mm, which falls well within the prescribed 30–50 mm range for handrail profiles, allowing for a secure and comfortable grip for users of all ages. Each handrail terminated with returned ends to minimize snagging hazards and comply with safety requirements.
The balustrades were fabricated to meet the structural integrity and safety performance criteria outlined in AS/NZS 1170.1 (Structural Design Actions – Part 1: Permanent, imposed and other actions) and AS 1657 (Fixed platforms, walkways, stairways and ladders). They provided compliant fall protection along the full length of the ramp, and were constructed using fully welded steel with minimal deflection under load. The ramp itself adhered to the maximum allowable gradient of 1:14, with compliant landing intervals incorporated every 9 m as mandated under the National Construction Code (NCC), Volume 1, Section D and Volume 2 for Class 9b buildings.
The fabricated components were finished with a hot-dip galvanised coating in accordance with AS/NZS 4680, ensuring long-term corrosion resistance, especially critical in external school environments subject to frequent use and weather exposure. Fixings and anchorage systems were selected and installed for high durability, load transfer efficiency, and tamper resistance — essential criteria for school infrastructure.
A final compliance check was conducted in alignment with the Disability (Access to Premises – Buildings) Standards 2010, ensuring that all installed elements contributed to a universally accessible and safe environment for students, staff, and visitors. The outcome is a robust, standards-compliant access solution tailored to the specific needs of an educational setting.
Given the zig-zag configuration of the ramp and the architectural requirements of the site, our fabrication team adopted a modular approach to streamline installation while maintaining structural integrity and compliance. All balustrades and dual-height handrails were pre-fabricated in our workshop in 6.5-metre modules, designed to align precisely with ramp turns and landings. This modular system allowed for efficient transport, reduced site congestion, and minimized welding activities in a live school environment.
The handrails and balustrade uprights were cold-formed and precision bent using CNC-controlled pipe bending equipment to match the directional changes of the ramp layout. This ensured a consistent 42 mm diameter profile throughout the system, without flattening or deformity at the bends — a key requirement under AS 1428.1 for maintaining grip uniformity. All joints within each module were TIG welded in the workshop, providing a clean, structurally sound finish that minimized visible heat-affected zones and reduced post-weld surface preparation.
On-site, the 6.5 m modules were positioned, aligned, and joined via full-strength butt and fillet welds, ensuring continuous handrail runs across ramp transitions and corners. Where necessary, welding was carried out in accordance with AS/NZS 1554.1 – Structural Steel Welding, with certified welders performing all site joins. To ensure visual and corrosion performance continuity with the hot-dip galvanised workshop finish (AS/NZS 4680), all on-site welds were first cleaned, then touched up using an epoxy zinc-rich primer, and top-coated with a silver zinc spray. This approach delivered a seamless aesthetic and long-term corrosion protection that matched the galvanised base coating, even under close visual inspection.
This combined off-site and on-site fabrication strategy allowed us to maintain tight quality control in the workshop while adapting effectively to the complex geometry of the installed environment, delivering a durable, compliant, and visually cohesive result.
1. 42.4 x 3.2 mm CHS Mild Steel Pipe (Stanchions & Horizontal Members, Including Handrails)
This circular hollow section (CHS) pipe was used for all vertical stanchions and horizontal members, including the upper and lower handrails at 900 mm and 700 mm respectively. The 42 mm external diameter complies with AS 1428.1 for accessible handrail systems, providing a consistent grip surface and clean visual alignment across the entire balustrade system. The 3.2 mm wall thickness offers excellent structural integrity for public-use environments.
2. 12 mm Mild Steel Round Bar (Baluster Infill Rods)
Installed vertically between stanchions to act as infill barriers, these 12 mm diameter round bars prevent climbing and meet the <125 mm spacing requirement under the National Construction Code (NCC). The solid profile provides durability and resistance to deflection while maintaining an open, visually unobtrusive appearance.
3. Laser-Profiled 10 mm Mild Steel Base Plates
Each base plate was laser-cut from 10 mm thick mild steel to match the precise geometry of the ramp and ensure accurate positioning of stanchions. Slotted anchor holes were incorporated to accommodate fixing tolerances and ensure secure mechanical anchoring to the concrete ramp surface. The laser profiling ensured clean, burr-free edges for safe handling and consistent welding performance.
4. Structural Fixings and Anchors
All base plates were fixed using high-strength mechanical anchors — either chemical or expansion anchors — chosen based on slab conditions and loading requirements. Stainless steel (A4/316) fasteners were used throughout to provide corrosion resistance suitable for external environments.
5. Protective Coatings
Join the Sunshine Coast families choosing us for quality panels, hybrid inverters and battery storage that stand the test of time.
Sandy Electrical Solar specialises in tailored solar and battery systems, EV charger installations and ongoing support. Based on the Sunshine Coast, we deliver accredited installs using only premium brands, designed for local conditions and built for long-term performance.
ACN: 667 837 845
ABN: 80 421 105 614
LIC: 91217
Copyright © 2026 Sandy Electrical. All Rights Reserved.