How to build deck railing?

[plumbuma]

Hi all,

I'm looking to build a balustrade/handrail system similar to the below for a small outdoor balcony: 

Just curious to see what peoples suggestions are on the best way to approach:

1) Getting the vertical aluminum bars (cant seem to find these pre-cut - is the only option to make my own out of a long piece?)

2) Best way to attach these to the wood (i.e. lots of pre-drilling vs some sort of attachment)

Thanks in advance

[EricL]

Hello @plumbuma 

Welcome to the Bunnings Workshop community. It's sensational to have you join us, and thanks for sharing your question about installing deck railing. 

I was looking at the Bunnings online store for aluminium bars and the only one I could find suitable for your balustrade was the Metal Mate 25 x 1mm 3m Aluminium Round Tube. Because it is unpainted you have the opportunity to paint it to your favourite colour. But before you begin, I suggest having a look at your local council's rules and regulations regarding the installation of a balustrade on your deck. I'm sure there are rules regarding height requirements and bar/baluster size/spacing that must be met.    

In regards to assembly, I can only suggest keeping it simple, the more complex it is the more time it will take to put together. In line with this philosophy, it would be simple to just drill into the timber to slot the bars in place. To make the drilling uniform, I suggest building a jig drilling guide that will make it less tedious. Should the council require a plan, I suggest engaging the services of a local draftsperson, they will be aware of the rules and regulations in regards to building and installing a balustrade. 

I recommend using timber that is treated to the level of H3 and nothing lower. The timber used outside must be rated for outdoor use and should be able to withstand insect attack.

Let me call on our experienced members @JoeAzza, @Nailbag and @Dave-1 for their recommendations.

If you have any other questions we can help with, please let us know.

Eric

[Dave-1]

Afternoon @plumbuma 

That would be a nice looking deck for sure!

The handrails (And yes check with what is allowed in your council area as @EricL has suggested) would be pretty easy.

Top timber bar with holes drilled all the way through and teh bottom timber rail holes half way through. With a smaller hole all the way through for water to escape. A drilling jig would really speed things along.

The top flat rail would hold the bars in with no chance of them coming out. The rectangular timber frame can be made easily to fit between the posts first. For the metal bars, I would visit a local metal fabricator or  have a look up on google for "tublular steel" I like steel over aluminium as it will be a stronger product, not that aluminium tubes are weak lol I would paint them in rust proof paint first. 

H3 timber for sure, Think the minimun height of a handrail is 900mm for me (and yes could be different elsewhere) I would also keep in mind to have your posts from ground to high, I get nervous about handrailposts that arnt extended down to teh ground. Dosnt have to be but I find them stronger.

Dave

[plumbuma]

Thanks for the feedback @EricL and @Dave-1

@Dave-1 - You are right. Stainless Steel would be the better option.

This seems to be a cost and time effective option Metal Mate 16 x 1.2 1m Galvanised Steel Round Tube - 1m at $5.12 each.

Current NSW rules say railing height must be a minimum of 1m; so the above 1m tubes + the frame width should be more than sufficient (without going overboard) and save me cutting lots of metal.

@EricL - is it safe to assume any outdoor/dressed timber will be appropriately rated?

For context, i was planning to build the frame out of Merbau. Not decided on specifics, but similar to the following:

Post - https://www.bunnings.com.au/90-x-90mm-2-4m-post-gl17-pre-oiled-merbau-dar_p0549667

Frame - https://www.bunnings.com.au/42-x-28mm-2-7m-fj-pre-oiled-merbau-screening-28mm_p0177439

Hand Rail - https://www.bunnings.com.au/140-x-42mm-5-4m-handrail-merbau-fj-pencil-round-select-140mm_p0063047

[EricL]

Hi @plumbuma 

As long as it says H3 then it can be used outdoors. Please note that some pine pieces are finger jointed and are not safe to be used for framing so be aware of this. Merbau timber is perfectly ok to be used outdoors. But just to be on the safe side it's best to make sure that it is on the approved materials list of the local council.

If you need further assistance, please let us know.

Eric

[JoeAzza]

Hi @plumbuma 

I agree with @EricL and @Dave-1  check with council first to see what is required, in the meantime I found this information online that may help you.

https://www.google.com/imgres?imgurl=https%3A%2F%2Fwww.aussiebalustrading.com.au%2Fwp-content%2Fuplo...

[Nailbag]

Hi @plumbuma 

Nationally any deck above 1m requires a permit. Then balustrade height and spacing of there vertical pieces need to also comply.

The best way to tackle this in my opinion once plans approved would be:

Avoid treated pine for posts as these will only twist and split. My recommendation is dressed Cyprus.

Build each balustrades section as stand alone projects. Fit the bottom rail first and definitely don't consider stainless tubing unless your budget is unlimited and especially if you're going to paint them. Aluminium will be the easiest to work with being easy to cut, lightweight and don't rust. If you're using 20mm tube, then use a 20mm spade bit or hole saw to make the rebates for the tubes. These only need be 10-15mm deep. 

I would recommend dressed 140mm x 40mm Merbau for the hand rails as this is a very stable timber. Parallel rebated 75mm batten screws will provide the best fixing. These can be concealed using an off-cut and a plug cutter to fill the rebates in.

Regards, Nailbag.