How to Repair Aluminum Handrails

Due to a bad storm last April my balcony aluminum handrails were damaged. The handrails/balcony were installed about 20 years ago and the handrails been coated with some kind of white enamel paint are like new except some members which are now broken/bend.

All pcs are now on the ground but trying to take them apart for the repairs seem like a big challenge. Looking at the cross section all pcs are bolted together with 1/4" screws but to access these screws I have to remove the aluminum covers and removing the covers is the challenge. The covers are press fit to snap into grooves and if I force the covers (each cover is 6 feet long) it will bend it and I will not be able to re use it.

My question: searching I could not find anything similar and I wonder if you happen to know how to remove these covers.

Thanks

 

Personally, I would replace. Maybe someone else will have repair advice.

 

Replace.

Many of those covers are designed to be installed... but not really removed. They assemble the fence then hammer/snap the cover into place. Plus, if the railing is bent or mangled it will make it even more difficult to remove the covers.

You can't fix broken, so you'd need to find suitable replacement parts. And, the aluminum will be difficult to straighten without leaving waves, kinks or even tear the metal. It's one of the lowest cost railing you can find and not designed for repair so replacement is usually the solution.

 

Somehow I was expecting this kind of an answer because of the way the covers snap into place. I did however ask around for replacement at first but the cost of $5,000 was ridiculously high. 20+ years ago I paid about $4,000 balcony included.

Don't think I will do anything before the winter so it gives me time to think for alternatives.

Many thanks

 

I have a pile of aluminum fencing/railing that I have collected over the years. Because it's difficult to repair it often gets thrown away or recycled. You can try checking Habitat for Humanities and other places that sell second hand building supplies. You could get lucky and find what you need.

 

I am not sure but I believe those remove by pulling the bottom edge out and pivot toward the top. You may need to use a very small screwdriver or pick to get behind the cover on the bottom to release it from the rail. Loosen the entire piece before attempting to remove it from the top side.

 

Thanks for the tip Pilot Dane.

badeyeben, good point and I just did what you described but the part deforms as I go along to lift one side and I stopped.

Since one side of the handrail is intact as you can from the 1st picture, I intent to put up the other 2 sides the best I can as soon as we get a good weather. The covers are just for looks and I think after I remove them I can force them back into place and where they don't snap I will use screws to hold them down.

Next summer I may install a new set something like this video which looks pretty easy.

https://www.youtube.com/watch?v=w62A0bW2ZoY&t=403s