The majority of Bailey industrial stepladders are manufactured using a Punchlock and swaging process in their tread to stile connections. This process has been widely used in manufacturing aluminium and fibreglass extension ladders for many years, due to the rigidity of the rung to stile joints.
The swaging process forms the end of the tread shape by expanding out and rolling over material through the stile to form a tight connection. Unlike a traditional riveted connection the swage forms into voids to leave no clearances that can work loose over time.
Double Hollow Tread
Bailey’s unique double hollow tread has distinct advantages over the traditional ‘C’ section tread shape due to the fact that 2 hollow sections resist twisting forces. (ie. Torsional rigidity). The entire ladder frame has increased rigidity and stiffness, therefore reducing the need for additional bracing.
This unique tread shape also has benefits that resist bending compared to a ‘C’ section treads due to the upper and lower webs being supported by flanges top and bottom. This tread shape has minimal deformation under heavy loads. Unlike ‘C’ section treads that only have 1 web that is supported at the top, so they tend to splay out under heavy loads. This requires the ‘C’ section tread to be of heavier gauge material or needing additional bracing.
Solid triangular bracing provides a strong support between 2 different members. Mostly used to stiffen the tread to stile connections. Tri-bracing supports over a longer distance along the stile and tread compared to a strip brace which only supports at its top and bottom points of contact. The solid triangular shape closes off any open voids on the ladder frame that could catch clothing or body parts.
Bailey Ladders design and test ladders to ensure they are strong and safe. By using these unique manufacturing processes and designs listed above they are able to reduce the overall weight of the ladders. High strength 6000 series aluminium alloys are employed to reduce weight and minimize the need for additional structural supports. That is why a Bailey ladder weighs less than its equivalent competitors ladder, thus reducing fatigue from shifting a ladder continuously throughout the day.