US Patent 6866117 Light weight ladder systems and methods

A method for manufacturing a rail for a ladder. The method may include pultruding in a longitudinal direction, a rail having a selected cross-sectional shape. The rail may then be cut to a predetermined length at a distal end. A force may be applied, in a lateral direction, to the rail to form a curvature therein. The curvature may be characterized by a flared portion, a straight portion, and a curved region providing the transition therebetween. The rail may be held at the desired curvature for a time selected for the rail to take on the curvature substantially permanently. The force may then be removed and the rail may be assembled into a ladder.