Installation Guide to install a 4 Steps Handrail with Flexi Elbow

Tools & Materials:

• Stainless steel pipe (handrail)
• Flexible elbow (stainless steel)
• Core drill (for concrete, masonry, or soil)
• Structural grout
• Rivets (stainless steel, appropriate size for pipe and elbow)
• Rivet gun (for securing rivets)
• Rivet mandrel (size matching rivet size)
• Grout mixing bucket
• Allen key (optional for other parts of installation)
• Drill with drill bits (appropriate for core drilling and rivet holes)
• Measuring tape (in mm)
• Level
• Pencil or marker
• Pipe cutter (if necessary)
• Trowel or grout-spreader tool
• Cleaning rags or sponge

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Step-by-Step Installation for Anchoring Pipe with Core Hole, Structural Grout, and Rivet-secured Flexible Elbow (For concrete floor, you can use the long base plate to simply the work):

Step 1: Measure and Plan

• Measure the height for the handrail. A common height range for a handrail is between 865 mm and 965 mm from the finished surface of the ground to the top of the handrail.
• Mark the locations where the pipes will be installed. This is usually done at the base of the stairs (or along the path of the handrail).
  • Ensure that the spacing for the pipes is uniform and that the handrail will be level once installed.
• Ensure the core hole location is correct. The holes need to be positioned where the pipe will anchor securely to the ground.

Step 2: Drill the Core Hole

• Use a core drill (with a diamond bit if drilling into concrete or masonry) to create a hole into the ground where the pipe will be anchored. The hole size should accommodate the diameter of the pipe and allow space for the structural grout.

  • For concrete or masonry floors, drill a hole at least 100 mm deep (depending on the length of the pipe that will be inserted).
  • For soil or earth, the hole may need to be deeper (around 200 mm or more) depending on the pipe's length and soil type.

• Clean the core hole to remove dust and debris. This will help ensure a strong bond between the grout and the surrounding material.

Step 3: Prepare the Pipe for Insertion

• Cut the stainless steel pipe to the required length using a pipe cutter.
• Ensure the pipe is cut to the correct length based on your measured height from Step 1.
• Insert the flexible elbow onto one end of the pipe.
  • Flexible elbows are typically adjustable, so you can rotate them to the desired angle.

• Drill holes for the rivets in the pipe and flexible elbow. You will typically drill two holes for each connection point, making sure the holes align properly on both the elbow and pipe.
  • The drill bit size should match the size of the rivet you're using (usually around 3.2 mm to 4 mm in diameter, depending on the rivet size).

Step 4: Install the Flexible Elbow

• With the flexible elbow now attached to the pipe, position it at the base (or top) of the staircase, or wherever the first support point is needed.
• Make sure the elbow is oriented correctly, as it will guide the direction of the handrail.
• Adjust the angle of the flexible elbow so that the pipe will connect to the next elbow or part of the handrail at the right angle.
• Double-check the alignment of the flexible elbow to ensure it is positioned correctly for the overall handrail installation.

Step 5: Install the Rivets

• Insert the rivets into the drilled holes of the flexible elbow and the pipe. Make sure the rivets are properly aligned.
• Use a rivet gun to securely fasten the rivets. Follow the rivet manufacturer's instructions for the correct setting.
  • As you use the rivet gun, it will pull the mandrel (the central pin) and squeeze the rivet to securely hold the elbow and pipe together.
  • Ensure the rivets are tightly secured, ensuring a strong, permanent connection. Repeat the process for each hole if there are multiple rivets used.

Step 6: Mix and Prepare Structural Grout

• Prepare the structural grout by following the manufacturer’s instructions on mixing. Typically, you'll need to add water to the grout powder and mix until it forms a smooth, pourable consistency.
  • Tip: Mix the grout in small batches so it doesn’t set before you have a chance to pour it into the hole.

Step 7: Insert the Pipe with Flexible Elbow into the Core Hole

• Insert the bottom end of the pipe (with the flexible elbow attached) into the core hole.
• Ensure that the pipe is aligned correctly, with the flexible elbow in the proper orientation.
  • Check the height and angle to make sure it is at the correct level for your handrail.
• Use a level to make sure the pipe is vertically aligned and the elbow is positioned at the correct angle.

Step 8: Pour Structural Grout into the Hole

• Fill the hole with structural grout around the pipe, ensuring that it surrounds the pipe fully.
  • Tip: You can use a trowel or a grout-spreader tool to spread the grout evenly inside the hole and ensure that it fills all gaps around the pipe.
• Pack the grout tightly around the pipe to ensure a solid connection and maximum stability.

Step 9: Allow Grout to Set

• Let the structural grout cure for the recommended amount of time. This typically takes 24 to 48 hours, depending on the product and environmental conditions.
  • Ensure that the grout has fully set and hardened before moving on to the next step.

Step 10: Secure the Handrail to the Pipe

• After the grout has fully set and the pipe with the flexible elbow is securely anchored, you can attach the handrail to the pipe/ post.
  • If you need to, attach the flexible elbow to the next section of the handrail.
  • Install additional elbows or connect the handrail along its path as needed.
• If necessary, attach the handrail to the flexible elbow using Allen key screws, ensuring a secure connection.

Step 11: Test the Stability

• Test the handrail’s stability by gently pulling or pushing on it to ensure that the pipe is securely anchored in the ground and the handrail is sturdy.
• If the pipe feels unstable, you may need to add more grout or adjust the installation.

Step 12: Final Adjustments and Cleaning

• Smooth any rough grout edges around the hole using a trowel or sandpaper for a clean finish.
• Clean the handrail and pipe using a stainless steel cleaner to remove any fingerprints, dust, or marks left during installation.
• If the installation is outdoors, you may want to apply silicone sealant around the pipe where it meets the ground to prevent moisture ingress.

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Additional Tips:

• Use high-quality structural grout: Make sure the grout is suitable for the surface you are working with (concrete, masonry, or soil).
• Allow grout to cure fully: Rushing the curing process can result in weak grout, leading to instability. Always allow it to fully set.
• Check for stability regularly: After installation, periodically check that the pipe remains secure, especially if the ground conditions change (e.g., with settling soil or wet conditions).
• Ensure rivet placement is correct: Rivets should be placed in areas that will provide the strongest bond between the flexible elbow and the pipe.
• Use a pipe spacer (optional): If you're working with a particularly wide core hole, you can use a pipe spacer to help hold the pipe in place while the grout sets.