Aluminum Rungs
All rungs are 1-1/4" diameter by .065" wall thickness.
(Standard Rung), unless your section width is wider than 24". In this case, you
probably have heavy rungs - 1-1/4" diameter by .105 wall thickness.
Note: All replacement rungs are supplied 24" - standard .065
wall.
To remove any welded rung from the rail or plate, you must use a rung reamer tool.
There is no need to replace the rung plates unless they are damaged.
The reamer tool pilots itself in the rung hole, and cuts only the
old rung away, thereby leaving-the proper size hole for the new rung to be welded in
place. If our standard reamer tool will not fit inside your rung - be sure the
ladder is a Duo-Safety Ladder and check the width of the section. If the section
width is over 24" wide - you have heavy rungs in that section. Heavy rungs are
supplied to meet the N.F.P.A. load rating in all sections wider than 24" wide.
In these cases you must order our Heavy Rung Reamer Tool and heavy rungs for
replacements.
The reamer tool is powered by a 1/2" drill. (Fire Dept. Supplies)
1. Insert in damaged rung.
2. Start drill and use very slight pressure to start the cut.
3. Cut through the weld and inner plate crimp to remove the old rung.
4. Repeat the process on other rail/plate. (Remove all debris)
5. Slide new rung through both rails and mark for length and cut same
with hack saw.
6. Hold rung flush and reweld the joint. (We suggest Heli-arch/ wire
feed)
7. If you have replaced more than 3 rungs per section, we suggest you
order and use our hand rung expander tool to expand the rung to the inner plates. (Not
used on heavy rungs or less than 3 rungs per section.)
Duo-Safety Ladder Corp. ladders all depend 95% on the welded rung joints to hold all
ladders together. The minimum yield of our welded joint is 8,000 P.S.I.
The expansion process on the inner plates is a 5% back up system to help protect the weld
joint from flexing and cracking.
Thus- if you only replace a few rungs per section - you do not need the expander tool. But
if you replace more than 3 rungs per section, we suggest you use the expander tool.
RUNG EXPANDER KIT:
For field use to replace rungs in
any Duo-Safety aluminum ladders, please order and use our rung expander kit if you are replacing more than
three rungs in any one section.
The rung expander kit consists of: 1. Hand rung expander tool. 2. Rung reamer tool. 3.
Instruction sheet.
You remove the damaged rung with the rung reamer tool and your 1/2" drill motor. This
tool cuts the old rung away from the ladder rail and inner plate assembly and leaves the
proper size finished hole to be able to re-weld the new rung into the rail. (We suggest
Heli-arch welding). You then finish the job with the hand rung expander to expand the rung
tight on the inner plate assembly (see instructions with kit).
There are two plans available for use of the Rung Expander Kit (rung expander tool & rung reamer tool) or Rung Reamer Tool only.
(1) Loan Plan - the rung expander kit or rung reamer tool only is shipped on memorandum billing - a credit is issued upon its return. The only charge is
for shipping. (2) Purchase Plan - the rung expander kit or rung reamer tool only may be purchased outright. See our Price List for current pricing.
Extra rungs and plates are billed F.O.B. Oshkosh, Wisconsin.
If you still have questions, please call 920-231-2740. See our Price List for current pricing.
