Fabricating a bollard that performs as intended—whether for safety, traffic control, or architectural enhancement—requires more than selecting a pipe and welding a cap. Each detail in the fabrication process directly impacts performance, lifespan, installation, and cost. Below is a detailed overview of critical considerations when specifying or fabricating bollards for your project.
Custom features may be added during fabrication to meet functional requirements or site-specific needs.
Chain Loops & Connection Tabs: Welded loops or tabs allow chains to connect bollards for flexible pedestrian or vehicle control.
Lifting & Handling Points:
Through Holes: Drilled holes (typically near the top) allow for rigging bars when heavy equipment is used to lift bollards.
Pad Eyes / Eye Bolts: Welded lifting points provide a secure and repeatable method for hoisting and placement.
Welded Handles: Welded to the lifting points on removable bollards provide improved ergonomics when lifting posts manually.
Locking Mechanisms: Removable bollards may require fabricated sleeves, tabs, internal pins, or padlock receivers to secure the bollard in place. Design should consider ease of use and long-term durability.
The strength of any embedded bollard starts below grade. Proper embedment depth, size and reinforcement ensure structural integrity under impact or stress.
Embedment Depth: Deeper embedments increase load capacity and resistance to force. Standard depths range from 18" to 48"+, depending on the application. Hole sizes from 12” to 48” are typical (based on bollard application)
Footing Design: Engineering may require concrete footings or reinforced spread footings depending on soil type, frost line, and load requirements. Designing in an array style greatly increases performance but does have a significant impact on installation costs.
Reinforcement: Welded rebar cages or stub-mounted rebar increase the bond to concrete and distribute impact forces. Adding through-holes, welded attachments and embed plates are also very effective tools for strengthening the embedment.
Surface treatment protects your investment and contributes to overall aesthetics.
Galvanizing (Hot-Dip or Cold Spray): Provides long-term rust resistance. Hot-dip galvanizing is most durable but must be accounted for during design (e.g., vent/drain holes).
Epoxy/Urethane Paint Systems: High-gloss, fade-resistant, and rust-inhibiting. Our two-part systems are blast-prepped for superior adhesion and performance.
Powder Coating: Offers smooth finishes in RAL-matched colors. Suitable for non-galvanized parts or over properly prepped steel.
Polysiloxane / Polyaspartic: High-performance industrial coatings with excellent UV and chemical resistance. Often used where galvanizing is restricted by runoff regulations.
Material choice is critical for long-term performance, corrosion resistance, aesthetics, and budget.
Carbon Steel: Most common and cost-effective. Available in various schedules (wall thicknesses). Requires protective coating.
Stainless Steel: Ideal for corrosion resistance and modern aesthetics. Often used in coastal areas, entryways, or where visual appeal is prioritized. Type 304 is typical; Type 316 is used in marine or chemically aggressive environments.
Other Alloys: Aluminum or specialty metals may be used for decorative or lightweight needs but are rare in high-strength applications.
Preventing water intrusion is essential to avoid corrosion and freeze damage.
Domed, Sloped, or Angled Caps: Direct water away from the bollard’s interior.
Wet-set caps: Provide the look of a welded cap but allow for concrete filling when installed
Weep Holes: Strategically placed weep holes allow moisture to escape from embedded or filled bollards.
Sealed Caps & Welds: Fully welded top caps and continuous seams help keep water out of the bollard’s interior but do prevent the bollard from being filled with concrete.
Custom fabrication should align with project architectural plans, municipal specs, and engineering requirements.
Plan Review: Details like baseplate size, sleeve dimensions, and height must match the construction documents.
Height & Diameter: Ensure the correct visual scale and protective coverage. ADA and other codes may dictate clearance and spacing.
Value Engineering: Identify opportunities to reduce cost without compromising performance—e.g., substituting materials, reducing wall thickness, or combining functions (e.g., removable + decorative).
Reinforcing above-ground strength ensures bollards perform under stress and endure long-term use.
Stiffeners: Horizontal or angled stiffener plates can significantly increase the bollard’s ability to resist deflection, especially in vehicle-resistant applications.
Concrete-Filled Pipe: Filling the pipe with concrete enhances rigidity and mass, minimizing deformation and damage from vehicle impacts.
Weld Quality: All structural welds should meet AWS standards; continuous welds at critical seams help avoid moisture ingress and stress cracks.
Fabrication must consider the unique needs of the install location.
Urban & High-Traffic Zones: May require tighter spacing, integrated reflectivity, and hardened materials.
Industrial & Warehouse Facilities: Typically demand heavy-duty construction, forklift visibility (yellow paint, reflective tape), and compatibility with concrete or asphalt.
Parking Structures: Lighter-duty bollards may suffice but must account for space constraints, vehicle height, and drainage.
Reflectivity: Add reflective tape or high visibility coatings to increase visibility in low-light or high-traffic environments.
Letters & Numbering: Numbers/letters are often added to mark the bollards purpose (e.g., indicating a danger like a drop-off, marking a handicap parking area or restricted zone).
Sign Mounting: Reflective sings allow for easy integration with rectangular bollards or bollards with sign posts incorporated in them.
Every fabrication detail—whether structural, aesthetic, or functional—should be guided by the end use of the bollard. Whether you’re protecting storefronts from errant vehicles, defining pedestrian zones, or adding architectural detail to your site plan, our team can help you engineer the right fabrication strategy from the ground up. With thousands of designs and decades of experience, we tailor every detail to ensure you get the durability, performance, and compliance your project demands.
