Installing Solar Bollards with Flanged Surface Mountings

Reliance Foundry solar bollards can be installed in existing concrete with flanged surface mountings. This installation method uses drop-in inserts to secure the flanged base. Drop-in anchors should only be installed in fully cured concrete that is at least 4″ thick.* All measurements in this installation guide assume a bare, level concrete surface.

It is important to note that with this installation method, the lighting bollard will offer little impact resistance. The function of the bollard is primarily for lighting and architectural or landscape highlighting. Solar bollards are self-contained devices and require very little ongoing maintenance.

PARTS LIST

#PARTQTY
1Flanged Bollard Base1
2Bollard Solar Light Cap1
35/8″ Drop-In Concrete Insert3
45/8″ Washer3
55/8″ Hexagon Socket Button Head Cap Bolt3
61/4″ Hexagon Socket Button Head Cap Bolt Tamper Resistant3

Installation Equipment

7/8″ Masonry Drill Bit5/8″ Insert Setting Tool (or equivalent)
3/8″ Hex KeySpecial Hex Key
Broom/Pressure WasherVacuum
ChalkHammer
Hammer Drill or Rotary HammerLevel
Measuring Tape

NOTE

  • To protect the finish, keep bollards in original packaging until the exact moment of installation.
  • Handle with care to avoid scratching or damaging bollard surfaces as abrasions will lead to rust.
  • Once scratched, bollards cannot be repaired to original form without re-finishing the entire surface.
Diagram showing the parts list

Before Installation

Check for hazards
Always check for hazards such as water pipes, gas lines, and underground wiring before drilling.

Clean the surface
Dirt and debris can affect the line of sight and disrupt placement of the bollards.

Use a broom or pressure washer to clean the concrete surface prior to bollard installation.

Study the site plans
Site plans are generally created by the architect of the project.

Refer to site plans to locate and mark the precise center point of each bollard.

Designate your hole markings
Keep the bollard in its protective packaging. Place the bollard over each center point marking so that the bollard’s middle coincides with the center point.

Note: For asymmetrical light distribution, be sure to make necessary adjustments to the orientation now. Decide on the direction of the light and configure the hole markings accordingly. Once drilled and installed, there is no way to rotate the bollard.

Use chalk to create drill-markings for each bolt. For secure installation, ensure there is a minimum radius** of solid concrete around each mark.

Remove the bollard.

Drill the holes

Create pilot holes
Tap pilot divot holes in the center of each mark.

This will prevent the hammer drill or rotary hammer from drifting while boring the holes.

Set the depth control on the hammer drill (or rotary hammer) to 2-1/2″
If depth control is not available, mark 2-1/2″ on the masonry bit.

Drill the holes
Drill holes with a 7/8″ diameter and 2-1/2″ depth.

Drill on high speed, using the hammer function if available.

Check the masonry bit often to ensure it remains free of debris.

Diagram showing a drill making a hole with a 7/8" diameter and 2-1/2" depth

Secure the bollard

Clear and clean the holes
Clear the holes of all debris and/or standing water using the vacuum.

Diagram showing a vacuum clearing the hole

Tap the drop-in insert into each hole
With the slotted end facing down, drive the drop-in insert (A) down until the top of the drop-in insert sits flush with (or just below) the surface of the concrete.

Set the concrete insert
Insert a setting tool (B) into each hole, then hammer down.

If a proper setting tool is not available, an equivalent flat-end punch can be used.

This will cause the internal expansion plug to set the concrete insert in place.

Diagram showing the concrete insert being set with a setting tool and hammer

Place the bollard base near the concrete inserts
Keep the bollard in its protective packaging. Carefully place the bollard base near the installation position.

When ready to install, remove the protective packaging.

Set the bollard over the holes
Keep the bollard in its protective packaging. Carefully set the bollard base over the installation position so that the bollard’s bolt holes are directly on top of the drilled holes and concrete inserts.

When ready to install, remove the protective packaging.

Secure the bollard
Place the washers over the holes on the bollard and set the bolts into place.

Use a hex key to tighten the bolts until secure. Tighten bolts evenly in a cycle.

Diagram showing a hex key tightening the bolts

Install the solar light cap

Connect the battery
With the lighting assembly still in its packaging, locate the battery’s wire plug and connect to the 2-pin socket attached to the light fixture.

Once connected, the lighting fixture will run a test pattern and may flash for 3–5 seconds.

Note: If the light does not flash, please stop installation and contact Reliance Foundry’s sales department for assistance.

Secure the solar light cap
Remove solar light cap from its packaging.

Place the solar light cap on top of the shaft of the bollard.

Secure the solar light cap to the bollard base with the three bolts and tighten equally.

Note: For asymmetrical lighting, consider the lighting pattern. When attaching the solar light cap, twist it to the desired lighting pattern before bolting down.

Diagram showing three bolts securing the solar light cap to the bollard base

Inspect

Inspect the installation
From a distance, examine the plane of view.

Ensure the bollard is plumb to the surface, and the surface is flat.

Check the bollard for any signs of surface damage
Abrasions should be covered as soon as possible to prevent rust and ensure the proper life of the bollard. For damage repair or other servicing needs, please contact Reliance Foundry’s sales department.

Care and maintenance

Reliance Foundry manufactures its products to the highest design standards to ensure their durability. Reliance Foundry’s bollards are finished with long-lasting powder coating. In most North American environments, routine inspections and cleaning will ensure that bollards retain their aesthetic appeal. Proper care and maintenance are required to maintain the finish and ensure a full service life.

*Concrete insert manufacturers such as www.ucanfast.com recommend a greater concrete depth for drop-in inserts.
**Concrete insert manufacturers such as www.ucanfast.com recommend an anchor spacing of 6-1/4″, and a minimum edge distance of 7-1/2″ for 100% performance.

Diagram of solar bollard installed with flanged surface mountings
Solar bollards can be installed using flanged surface mountings.