Installing Metal Decorative Post Covers - New Posts in Existing Concrete
A proven method for bringing beauty to security posts
A proven method for bringing beauty to security posts
New security posts can be added to existing concrete surfaces with no loss to the area’s aesthetic appeal. With Reliance Foundry’s proprietary mounting system, Reliance bollards can be set over new steel pipe bollards to give them an aesthetic enhancement. By installing a security post in existing concrete and covering it with a Reliance Bollard, you add safety and ornamentation to a streetscape.
It is important to note that Reliance Foundry does not market its products as high security devices. Although Reliance bollards do act as safety devices and traffic guides, their function is primarily decorative. The level of impact resistance they will provide is directly related to the installation of the security posts on which they are set. The following are general guidelines for installing Reliance bollards over new security posts. To ensure that your security post will deliver an adequate level of impact resistance for your application, you may wish to consult an engineer or professional installer.
Installation Equipment Required
- Measuring Tape
- Chalk Line
- Core Drill
- Auger or Post-Hole Digger
- Dirt Tamper (optional)
- 1½" (38mm) Wrench
- ⅜" (9mm) Allen Key
- Touch-Up Paint (can be easily sourced at automotive part stores)
Surface Preparation and Determining Layout
* NOTE: Bollards should be left in their packaging until the exact moment of installation
- Ensure that underground utility lines and pipes pose no risk:
Because installing security posts requires penetration of the concrete surface, it advisable to check for water pipes, gas lines and underground wiring. A core drill, in advance of an x-ray, may be required. Taking the proper safety precautions can help to eliminate expensive “down time” and prevent accidents.
- Study the site plans:
Site plans are generally created by the architect of the project. The architect will mark the intended location of each security post on the plan. Ensure that the plan coincides with the site and familiarize yourself with the intended arrangement of the security posts.
- Designate where each security post will stand:
If the bollards are intended to be installed to create a uniform-looking straight line, many contractors find it beneficial to snap a chalk line. This will help determine the center-point of each security post that will hold a bollard. The center-point of each security post should be marked with chalk, spray-paint or a felt pen.
- Remove the concrete over the security post’s installation area:
Center a core drill over the security post’s designated mark and remove the concrete. The diameter of the hole created should be at least 6” bigger than the security post.
- Drill the installation hole:
You may wish to learn the site’s frost line in order to determine the appropriate depth of the hole in which the security posts will be installed. An area’s frost line depth can be established at local building inspection departments. Generally, holes are 18” – 24” deep. Use an auger to create a hole that reaches the appropriate depth with a diameter that is at least 6” wider than the security post. You may wish to use a tubed concrete form to install the bollard.
- Set the security pipe in the installation area:
Ensure that the post is plumb with the surface and that the site is ready to receive the concrete.
Pouring the Concrete
- Mix and pour the concrete:
Ensure that the proper ratio of water and concrete mix is used. The concrete should have a similar texture to mouldable clay.
- Install the threaded rod:
Place the threaded rod in the center of the security pipe, when the concrete is being poured. Ensure that the rod does not extend above 32” from the finished concrete surface. Hold a level vertically against the side of the threaded rod and make certain that it remains plumb with the concrete surface.
- Allow the concrete to cure:
A lot of elements factor into a concrete surface’s cure time. Moisture in the environment and cool temperatures can both significantly slow the process. It is generally recommended that a minimum of 2 - 3 days wait should be given before beginning construction projects on new concrete surfaces.
Securing the Bollard
- Set the bollard near the security post:
With the packaging left on, carefully set the bollard near the installation position. Then, remove its protective packaging.
- Place the bollard over the security post and threaded rod:
Lift the bollard over the threaded rod so that the rod extends through the bollard’s receiver hole. The bollard should rest with the threaded rod exactly centered in the bollard’s shaft. Metal bollards can be quite heavy, depending on the model and material selected. To prevent accidents and injuries, the proper resources should be available to lift bollards into place or onto their mountings.
- Set the washer over the threaded rod:
Place the washer over the threaded rod so that it rests on top of the shaft of the bollard. Apply the 1” nut to the threaded rod and tighten it until the bollard is secure.
- Secure the bollard’s cap:
Remove bollard cap from its packaging. Place the cap on the top of the shaft of the bollard. Then, secure the cap to the shaft by tightening the three set screws with equal amounts of torque to ensure that the cap remains centered. The set screws are composed of stainless steel and the insert holes on the bollard cap are lined with stainless steel to prevent rust. Place the provided plastic caps over the heads of the set screws.
- Inspect the installation:
At a distance, examine the plain of view. All bollards should appear to be perpendicular with the surface of the concrete. On level surfaces, hold a level vertically against the side of the bollard to ensure that it is plumb to the surface.
- Check the bollard for any signs of surface damage:
If the bollard was scratched or scraped during installation, it can be repaired with touch up paint, commonly found at automotive stores. Abrasions must be covered to avoid rust and ensure the proper life of the bollard.
Care and Maintenance
Reliance Foundry manufactures its products to the highest design standards to ensure their durability. Reliance’s line of bollards are finished with a long-lasting powder-coating. This powder-coated finish will protect the bollard in typical North American climates, however, proper care and maintenance is required. In most environments, regularly-performed inspections and routine cleaning will ensure that a bollard retains its aesthetic appeal and does not become damaged by the elements.