Good Railing Design
Railings come in many shapes and sizes, and if you’re reading this article, you may be wondering where to begin when deciding what you’d like your new railing to look like. Many think primarily of how the railing will look, which is certainly an important query, but few consider the heart of what it means for a railing to be well designed. In this article, I will share my thoughts on a range of different elements to consider before solidifying plans with the contractor of your choosing.
Safety
An obvious place to start, but a topic with many elements that are not frequently discussed. Everyone knows a handrail can be an important part of making a home or building safe to enter, exit, or navigate inside, but not all railings are created equal in how well they fulfill their duty.
Material: Common materials used for railings include Steel and Aluminum. Iron and Wrought Iron in this day and age are nothing more than colloquial terms left over from days gone by. “Steel” is a vast umbrella term that covers a large range of applications and material properties. Through the advancement of our technology and techniques of developing metals, Iron and Wrought Iron are rudimentary materials erased from use in modern applications by the sands of time. Steel is a metal that has superb strength and durability, though it is heavy and susceptible to corrosion. Aluminum has excellent resistance to corrosion and is useful for how lightweight it is, but it lacks strength and rigidity. These, of course, are generalizations of two metals that can be developed to have a wide range of advantageous properties, but for the purposes of this article, I will be speaking exclusively about the grades of Steel and Aluminum that are commonly used in handrail applications.
In an effort to make production more and more economical, compromises have been made to the integrity and longevity of many products, and railings are no exception. Aluminum has become a staple in this industry. It is soft which reduces wear and tear on the machines that cut and form it into railings, making it economical to produce. It resists corrosions so lower quality finishes can be applied without the risk of rust showing through. The welding process is quick and leaves very little for finish grinding and deburring, and its softness makes finish grinding quick and easy. It is lightweight which makes it easy to handle, cheap to transport, and effortless to install. All in all, Aluminum railings sound like an excellent choice of material for building railings, and at face value, this would be true. The problem lies in the balance between cost and material properties. For Aluminum of comparable strength and durability to Steel, raw materials would cost 20-40% more in nearly all cases. If costs are kept equal between the materials (which is essential to large-scale manufacturers competing with these products) the sacrifices begin at the strength and durability of the material itself and extend all the way down to the hardware they are fastened with.
Common Aluminum railings will have roughly half the strength and stiffness of a comparable Steel railing. This gives users less confidence in the feel of a railing during use, and for good reason. Under moderate or high loading, like what may occur when slipping on a stairway and clinging to the railing for safety, the deflection that may occur could be alarming. If the injury is avoided, the railings have done their job, but they may not be in a condition to continue service after an event like this. To consider these products fairly, it is important to recognize they still have a place where they can be a fine option for your project. For features that are primarily aesthetic, decorative metalwork is allowed to be more delicate. Its primary role is to look nice and provide character to a space, and in this context, lightweight aluminum products are an excellent option. In the case where safety and reliability are desired, a steel railing is generally better suited for the application.
Means Of Construction: To touch on this generally, there are two primary means of construction. Welding, and fastening. Most railings are welded products, regardless of the material they are made from, making them strong, and generally require very little, if any, maintenance. Fastened railing systems on the other hand may be economical and easy to DIY but come with far more maintenance. Every joint and fastener becomes a potential point of failure, and when left in the elements long enough, the fasteners often become very difficult to re-tighten. This leaves a floppy railing that inspires very little confidence if one needed to rely on it for support and safety. These factors truly make it the “Landlord Special”. Easy to source, easy to install, easy to reach code compliance, and easy to leave in complete disrepair indefinitely.
Means Of Anchoring: There are a wealth of different types of anchors that can be used. If safety is desired long term, only a few should be considered. Epoxy anchored studs are great for aged concrete, brick, and hardscape, as it produces very little pressure that could cause cracking in the substrate. This method can be messy and more sensitive to weather conditions during the installation, making it a good option to consider when needed, but not necessarily the default for every situation. For newer concrete, or on larger pads, expansion and wedge anchors are an exceptional option. They are strong, simple to use, and easy to access, but they do produce lateral pressure that could risk cracking the substrate when used in the wrong application. Thread cutting bolts, like a Tapcon, can be a first-rate middle ground between the two options. They are gentle on the substrate while still offering excellent strength and ease of use. In any of these cases ⅜” anchors are the minimum size I would recommend. The last option, most commonly used in commercial construction: is core drilling and grout. This process cores out a pocket of the substrate so the railing can be set in place and grouted. This method requires specialized equipment, but is efficient and forgiving, making it advantageous for many builders who need volume over perfection. Anchors that are thinner or fall outside of what is mentioned above will likely not be up to the task of holding your railing firmly in place indefinitely. Your railing is truly only as sturdy as it can be if it is anchored properly, and cutting corners here is one of the most unfortunate ways contractors undermine what may otherwise be quality work. For a few dollars extra per anchor, you can have peace of mind about the stability of your railings for years to come. We think that is well worth the investment.
Layout: Does your railing meet the code requirements? If you were preparing to put your house up for sale, would your railing pass the inspection? Are the spindles spaced appropriately to be safe for children? Are they laid out in a way that could encourage curious children to climb? Truthfully, code requirement is a large topic that will receive a lot of attention in another article. Not only are there codes for accessibility, but there are state and local municipal codes that must be considered as well. Verifying what is required can be tedious and time-consuming even for those of us who do this for a living. Hiring a professional is one way you can be sure the railing will be suitable, and you can leave the headaches for someone else to sort out.
Longevity
Building a railing to last comes with several things to consider. To hit our target, the best place to start is to consider the common points of failure in railings.
Anchoring Failure: Likely the most common failure we see in the neighborhoods, a perfectly adequate railing that flops like a fish, or worse, a professional soccer player. This is most often caused by using cheap means of anchoring, including undersized anchors, or using anchors that will not stay tight over time in the elements. In some cases, a railing could be reinstalled to correct this issue. That being said, anchoring is the least expensive part of constructing and installing a railing. If that contractor cut corners on anchors, it is likely they cut corners elsewhere as well.
Tubing Rupture: Often mistaken for a rust failure, rupture can occur in hollow profiles that over time will allow water to collect inside of the railing. This will cause rust no doubt, but the failure is more often the result of the freeze and thaw cycle happening inside of your railing. Water is a non-compressible fluid, which means that in the right conditions, freezing water can impart a tremendous force on any vessel that might contain it while it is transitioning from a liquid to a solid. Similar to soda cans exploding when they get too cold, your railing will do the same thing for the same reasons. Most often, this rupture will occur at the base of the railing legs where the water will collect, cutting the metaphorical Achilles heel of your railings.
Rust: This is the slowest means of failure of your railing, but one that is very certain to happen if a railing survives long enough and does not fail in a more common way sooner. Like a river carving a canyon, even well-built products will show their age eventually. It is simply a matter of chemistry. Rust will often take hold more rapidly after a Tubing Rupture failure occurs. Once the structure is opened to the elements, the material will have increased exposure around the areas that are already most compromised.
Style
This component is most difficult to speak about objectively. Tastes vary and that isn’t a bad thing. Finding sample photos of a railing you like online is a great way to start the process with your contractor. Visualizing exactly what you are looking for is key in providing accurate pricing and timelines for your upcoming project. Some manufacturers will have catalogs that may help you decide, but custom builders may not, and using inspirational photos will be the best way to get everyone on the same page. Sleek and modern is simple and clean. Traditional molding and lambs tongues can match the aesthetic of a historic home. Everyone’s situation may be different. Ultimately, it is up to your contractor to ask the right questions to ensure they truly understand what matters to you most.
A Conclusion With Bias
This is the part where I give you an honest opinion based on the insight I’ve gained after building and repairing many railings over my career. To me, a well-designed railing must look good, it must be safe, and must be built to last. All three of these things are technically optional, but as an individual, if a railing project does not intend to satisfy all three of these elements, I do not have an appetite to take the project on. Building thoughtful and well-made pieces brings me joy and satisfaction, and to do anything less would merely work to pass the time, better left for those who find joy differently than I do.
To build something that looks good, understanding the tastes of my clients is the most important. Thoughtful layout, clean finish grinding, high-quality powder coating, and professional installation are the core of getting a beautiful railing. Cutting corners on any of these elements will show in the final product. Working with a contractor capable of delivering on each of these is paramount, and asking about the details of these processes will help you sort out which contractors have the attention to detail you require for your project. If a railing is to be powder coated, it may also need a plan for fastening. Once a railing is powder coated, it cannot be welded during the installation without damaging the finish in the affected area. Sometimes this is unavoidable, and a high-quality matching paint can be used for touch-ups. In certain situations, the paint may be more appropriate, and there are high-quality paints that will look and feel good for years to come. Consulting a professional painter in cases like this is a good way to ensure a successful outcome. More often than not, clever design and thoughtful construction can ensure that each section of the railing is small enough to be powder coated and handled for the installation. Multiple sections can be connected in a way that is tasteful, subtle, and strong. This is where a custom or high-end builder will show their true value. Every layout is different and designing a railing system to perfectly suit the area is a talent that not every manufacturer can provide.
To build something safe, using ⅜” or ½” anchors, properly chosen for the substrate is an important place to start. A Steel railing that is strong and stiff, when anchored properly, will inspire absolute confidence in the hand. It is important to feel the railing would support you should you ever need it. Perhaps you are young and spry, and your bones are still made of rubber. You may feel less concerned about your safety, and as a fellow kid (insert Steve Buscemi meme), I can relate. That being said, the few days a year you may have loved ones visiting for a birthday or a holiday, a railing that is safe and secure can give everyone involved more peace of mind. If you wouldn’t trust your railing to save your sweet old grandmother from breaking a hip, your railing isn’t a safe railing. And to shoehorn in the basics, your railing needs to be code compliant and built to keep the inspectors happy.
To build something to last, Steel is the most common material of choice. Perhaps most important to the longevity of a railing is the choice of material profiles. Square tubing and pipe are quite common to use both indoors and outdoors. I much prefer to work with a solid steel bar. Not only is it easy for us to work with, but it also cannot collect water and rupture over time. This is particularly important outdoors where it is most likely to occur. If it cannot collect water, it will only develop superficial rust as well, making it easy to touch up the finish years down the line if need be. Solid bar works well for modern designs that are trim and sleek, serving their purpose while leaving a room or patio airy and inviting. To mitigate concerns with rust further, a high-quality powder coat goes a long way. It not only looks good but feels tactile in the hand, speaking quality into the experience of using the handrail.
These are my recommendations, and you are welcome to come to your own conclusions. As always I welcome any questions you may have about the subject or a particular project you may have in mind.
