Welding aluminum and stainless steel railing or handrail


We weld railing and handrail such as aluminum railing, steel and stainless steel handrail, in place and on-site within property maintenance projects in Ontario. Our objective is to reduce the hazards caused by cracked, rusted, and broken structures in commercial, industrial and residential maintenance projects. We also fabricate and install new handrail and railing from materials described above. Our welding services offered for damaged handrail and railings vary pending their sustained damage and material used.  And focus on reduction of cost for welding repairs. We tend to accomplish most welding on site for aluminum, stainless steel and steel structures and only in very specific situations we resort to welding shop environment.

Repair of aluminum railing or stainless-steel handrail

Repair of aluminum railings or stainless steel handrail requires different welding equipment, welding consumables and different welding skills. These new, aluminum and stainless steel structures are much more expensive and later much costlier to repair. Most managers see aluminum railing as a better replacement for steel structure that resist corrosion and looks good. The stainless railing is mandatory at pools due to its high corrosion resistance and where a shiny stainless steel look is needed.

Repairs of aluminum railing.

Aluminum railing, generally speaking, resists corrosion. That is why more and more owners prefer this material. Unfortunately, most of the property managers forget that aluminum corrosion is a significant factor in damaging bottom of the posts that are being affected by snow melting substances. Additionally, these aluminum structures sustain damages due to vandalism. Vandals bend aluminum structures and try to remove web prongs. Most certainly, cracks are the most common structural damages of aluminum railing. These cracks develop due to
  1. deficient welding technique,
  2. improper selection of welding consumable: wire or rod
  3. too significant thickness differences between welded elements that makes aluminum welding much more difficult, or
  4. impact
In our crack repair service of aluminum railing and handrail, we focus on repair cracks and replacement of bent elements instead of fabrication of a new structure. For aluminum railing crack repairs we use
  1. our special aluminum welding rods that provide good results if aluminum walls is thicker than 3/16”,
  2. push-pull gun with 5xxx wire,
  3. spool gun with 5xxx thin aluminum wire, or
  4. combination of all these techniques.
Then all welds are smoothed with our abrasives.

Stick welding aluminum

The most comfortable technique is stick welding aluminum with our 4xxx welding rod since the repair can be done on-site. And in any weather for cost reduction. This aluminum welding rod helps us to accomplish projects on many bridges in Ontario.

Mig welding aluminum

We use less often our push-pull gun with our thicker aluminum wire in on-site welding. The wind impacts significantly our mig aluminum welding of handrails since it blows away the shielding gas. In less windy conditions, our welder prefers a shielding umbrella since it is more portable than the welding tent. Erecting the tent for welding in windy conditions is the last resort since it is not portable and increases the cost significantly. The cracks on very thin aluminum railings are done in the shop with our thinnest 5xxx wire using spool gun. In our welding shop, we have, additional regulations, proper setup control and we do not have to worry about wind.

Repair of stainless steel handrail

The stainless steel handrail is a common fixture in any inside or outside pool. And stainless-steel railing develops material cracks and weld cracks due to temperature fluctuations and inability to expand or contract freely due to the handrail or railing structure. Repairs of stainless steel handrail are complicated. These complications refer to:
  1. stainless steel alloy,
  2. thickness of material,
  3. shape of the crack, and
  4. access to power.
The stainless steel alloy impacts corrosion resistance and low quality older structures are prone to pitting. The low quality of stainless steel alloy displays typical rust discoloration leading to more severe rust damages. The situation can lead to a very strange procedures used by maintenance crew that attempts to remove rust from a low quality stainless steel handrail. Cracks developed in rusted low quality stainless steel handrail are difficult to repair. The main difficulties in cracks repair of more modern and better quality of stainless steel handrail refer to thickness of material. The handrail just look good with its decent diameter size elements. However, this material is so thin that Tig welding cracks located at some distance from T joint assembly can result in holes. In such cases, we have to resort to welding  with the thinnest wire on our Mig welding machine. Using our Mig machine, we attempt to increase the thickness of the surrounding the crack material and then weld the crack. Some cracks in stainless steel handrail are very long and repairing them in place is difficult and time consuming. In such cases, we tend to replace the section instead of repairing the crack. Access to power is always challenging in these projects. In outside pools we can draw power from generator for our precise Tig or Mig machines. But in this environment we must deal with windy conditions resulting with erection of welding tent. Therefore, we tend to approach repair of these structures in our welding shop, it this is possible. Access to power in indoor pool is always challenging and requires long extension cords and long setup. Fortunately, we do not have to deal with windy conditions there.

Repairs of steel railing and steel handrail

The steel railing and handrail rusts and even if you paint it regularly, within your property maintenance regime, every few years, it will still rust. We only weld repair the corrosion and rust affected areas by replacing them with new thick material. In this way, we avoid installation of  new structures. Therefore, we reduce cost of repair and increase utilization time. The material for old railing and handrail is usually much thicker in comparison to new structures. The modern structures just look bulky and strong. But in reality their very thin material develops holes quickly once the rust or corrosion settles. Therefore, our effort focus on preservation of thicker structure with replacement of parts with elements as thick or thicker as the old structure.

The steel railing and handrail post cause the most problems

In most projects, the affected by rust or corrosion areas are located at the bottom of the posts. Sometimes, even the base plate is in fairly good shape but the first 8” – 10” is corroded and holes are showing up through. The fabricator uses HSTS or black pipe for structure's post.  Over the years, the post bottom becomes much thicker at the bottom which is a standard sign of rust penetration. We replace bottom of the posts (up to 16”) with twice thicker material for all railing and handrail affected by corrosion or rust. If necessary, we also replace base plates that will be thicker and slightly bigger to accommodate anchoring. We use our flux cored welding machine to Mig weld the cracks on thin walled steel handrail structure. In this way, the weld repair can be done practically anywhere and at any weather. Most of the weld repairs are done on-site. Therefore, we drastically reduce the cost of weld repair in comparison to whole structure replacement. And we reduce the hazard time of faulty handrail or faulty railing due to quick turnover welding service.

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