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AS 1657 Handrail Design And Testing For FRP Guardrails
AS 1657 covers the design and installation of fixed platforms, walkways, stairways and ladders, commonly used in plants, processing facilities, treatment plants, rail stabling yards and other non-public access areas. It sets requirements for guardrail heights, rail layouts, toeboards, and structural performance to ensure safe movement around elevated regions.
Treadwell’s FRP handrail system is a bolt-together, modular, no-weld guardrail solution made from pultruded fibreglass-reinforced polymer (FRP). FRP combines glass fibre reinforcement with a resin matrix to deliver high strength, corrosion resistance and electrical non-conductivity, which is particularly useful in corrosive or electrically sensitive environments such as wastewater plants and substations.
Because FRP handrail components are proprietary and do not match the “typical” steel or aluminium sizes listed in AS 1657 Appendix A, they must be both engineered and physically tested in accordance with the test method in Appendix B and Clause 6.1 of the standard. Treadwell has conducted testing on its FRP guardrail system, applying the prescribed point and line loads and checking deflection and residual deflection against the standard’s criteria.
What this webinar covers
- Where handrails and guardrails are required under AS 1657
- Key dimensional rules, such as handrail height and intermediate rail spacing
- When a single top rail is not sufficient
- The difference between “standard” steel or aluminium guardrails and proprietary systems
- The AS 1657 Appendix B test method for guardrails, including loads and deflection limits
- Practical considerations, such as removable handrails and the influence of supporting members
Key Benefits
1. Clear interpretation of AS 1657 handrail requirements
The session explains, in plain language, how AS 1657 treats what most people call “handrails,” but the standard calls them guardrails. It clarifies:
- Guardrails are required on exposed sides of platforms and landings, except at obvious access points like stair or ladder openings and where adjacent structures are close enough to prevent falls.
- The top rail height must be between 900 mm and 1100 mm above the platform surface or the stair nosing line, with higher heights often recommended where falls are significant.
- You cannot rely on a single top rail. At least one intermediate rail is required so that the clear space between rails does not exceed 450 mm, and a toeboard is required where objects could be kicked off the edge onto areas people can access below.
This helps designers move from the abstract clauses in AS 1657 to clear, buildable layouts for real platforms and stairs.
2. Understanding when “standard” tables apply and when testing is mandatory
AS 1657 Appendix A specifies minimum component sizes for steel and aluminium guardrails, including angles, flat bars, and round or hollow sections. If you build your handrail using those member sizes and materials, the standard deems it compliant, provided the fabrication quality is appropriate.
However, any proprietary or non-standard system, such as Treadwell’s FRP guardrail, falls outside the scope of those tables. The webinar explains that in these cases, you must:
- Verify the system by structural engineering
- Test the guardrail assembly in accordance with Appendix B, using the loading and deflection criteria set out in AS 1657:2018
That distinction helps asset owners and specifiers know what documentation they should expect from suppliers.
3. Clarity on AS 1657 guardrail loads and deflection limits
The session summarises the test method for guardrails under AS 1657:
- Apply a concentrated load of 0.74 kN at critical locations such as the top of posts, mid span of the top rail and toeboards
- Apply a distributed line load of 0.55 kN per metre along the top rail and at other specified positions,
- Check that the total deflection under test load does not exceed 100 mm, and that the residual deflection after removing the load is not more than 20 mm
The webinar also stresses that deflection includes movement in the supporting member, for example, a channel or PFC that twists or yields under load. If the support deforms significantly, it can push an otherwise strong guardrail assembly beyond the allowable deflection.
This gives engineers and auditors a clear benchmark to verify that a system is not only sufficiently strong but also sufficiently stiff to be safe and comfortable in use.
4. Practical guidance on removable handrails and detailing
Removable or demountable handrails are often needed around rail lines, access hatches or heavy equipment. The video explains the trade-off:
- The handrail must be removable without excessive effort
- The connection must still be tight enough that there is minimal slack, so residual deflection remains below 20 mm when tested
By highlighting this balance, the session helps designers avoid details that feel convenient in theory but would fail the standard’s testing requirements in practice.
5. FRP handrails for corrosion and electrical safety
The webinar positions FRP handrails as a strong option where:
- Corrosion is a persistent problem for galvanised or painted steel
- Electrical conductivity is a concern, such as in substations, rail or power environments
FRP is a composite material that does not rust like steel and is naturally non-metallic, which can significantly reduce earthing and bonding requirements compared with conductive guardrail systems.
Combined with modular, bolt-together construction, this gives a low-maintenance, electrically safe guardrail solution that still meets the structural and testing requirements of AS 1657.
Applications
- Maintenance platforms and walkways
Back-of-house industrial areas, processing plants and treatment facilities that require compliant guardrails around elevated access ways defined under AS 1657. - Stairways and landings in plant areas
Internal and external stairs and landings that are not for public use but still require safe, compliant handrails with intermediate rails and toeboards. - Rail stabling yards and service pits
Platforms alongside trains where removable guardrails may be needed for access to rolling stock, while still meeting guardrail load and deflection test requirements. - Corrosive and high-risk environments
Chemical plants, wastewater treatment facilities, coastal infrastructure and other harsh environments where corrosion resistance and non-conductivity are important design drivers, and FRP handrails can reduce maintenance and electrical risk. - Retrofits and upgrades of existing access systems
Replacing ageing or non-compliant metallic guardrails with a tested FRP system that meets AS 1657, including situations where supporting structures must also be checked for stiffness and load capacity.
Key Moments
- 00:22 👋 Introduction to handrail testing and design as per AS1657 by Edward Titley.
- 00:37 📜 AS1657 outlines guidelines for the design of non-public fixed platforms, walkways, and ladders.
- 02:26 🧱 FRP handrails are preferred for corrosion resistance and conductivity compared to traditional metallic handrails.
- 04:35 🔒 Guardrails are required on exposed sides of platforms, with specific exceptions noted in AS1657.
- 05:15 📏 The required height of a handrail is between 900 mm and 1100 mm, increasing to at least 1,000 mm for significant fall risks.
- 06:12 ❌ Top rail-only handrails are non-compliant; intermediate rails must be included to meet safety requirements.
- 07:08 🛠️ A toeboard system is necessary where there is a fall risk, preventing objects from falling onto areas below.
- 08:07 📊 Appendix A of AS1657 provides material and component requirements for guardrails and handrails.
- 11:21 🚧 Proprietary handrail systems must be verified through engineering and specified testing according to AS1657.
- 12:15 💪 Testing requirements include point loads of 0.74 kN and distributed loads of 0.55 kN per meter with specific deflection criteria.
- 15:56 🔍 Testing consistency is crucial for safety, ensuring products are fit for purpose and meet project requirements.
- 19:30 🛠️ Corrosion-resistant fixings are essential in harsh environments; alternative socket or grouted methods can be used.
- 21:22 🔄 Handrails exceeding deflection limits due to aging or exposure should be replaced to maintain compliance.
Why Treadwell?
- AS 1657 aligned FRP guardrail system
Treadwell’s FRP handrail system has been designed and tested in line with AS 1657:2018, including Appendix B guardrail testing so that specifiers can rely on documented performance rather than assumptions. - Deep familiarity with standards and practical design
The webinar series demonstrates Treadwell’s working knowledge of AS 1657 and related standards, such as AS 1170 and AS 1428, and translates it into practical details that work on site, not just on paper. - Modular, no-weld construction
Bolt-together FRP components minimise on-site hot work, simplify installation, and enable easier repairs or modifications compared with welded steel systems. - Support from design through to implementation
Treadwell’s technical and engineering teams can assist with member selection, handrail layout, load checks and test documentation, and can work alongside independent engineers and certifiers to streamline approvals. - Fit for harsh environments
With FRP systems that resist corrosion and are electrically non-conductive, Treadwell can support long-life guardrail solutions in demanding industrial, coastal and utility environments where traditional metals may struggle.
