Overview
Our team at Zavza Seal was contracted to repair and restore warehouse guard rail safety barriers at a commercial facility in Syosset, NY. The barriers, critical for protecting personnel and property from equipment collisions, had suffered significant damage over time. Our experts assessed the damage and implemented a comprehensive repair plan to restore the barriers to full functionality and structural integrity.
The Problem
The facility’s safety barriers consisted of steel channels welded to I-beam posts, which were mounted on rectangular steel plates anchored into the concrete slab.
During our inspection, we found multiple issues:
- The concrete footings were compromised by repeated lateral impacts, leaving them cracked and weakened.
- Two of the steel channel barriers were bent and structurally damaged, making them unsafe.
- The existing welds and anchors were no longer providing the required strength to keep the barriers secure.
Given the extent of the damage, repairing the bent channels was not a viable option. A full replacement of the damaged steel channels and repair of the concrete footings was necessary to restore safety standards.
The Solution
Our team devised a targeted repair and replacement strategy that minimized downtime for the warehouse while ensuring long-term durability.
Step 1: Detachment and Preparation
We carefully detached the existing guard rail barriers from the damaged concrete slab and set them aside for reuse where possible.
Step 2: Concrete Footing Repair
- Using jackhammers, we removed the damaged concrete footings completely.
- Poured new wire-reinforced concrete footings to provide a solid foundation.
- While the concrete was still wet, we embedded galvanized steel threaded anchors to secure the future barrier installation.
- Repaired surrounding concrete using high-strength 5,000 PSI concrete.
- Installed 4.5 oz reinforced fibermesh sandwiched between two layers of 7,000 PSI waterproofing cement to further strengthen and protect the repaired areas.
Step 3: Steel Channel Replacement
- We used precision steel blades to cut the welds and remove the two damaged steel channels from the I-beam posts.
- Welded brand new steel channels in place, ensuring they met the original design specifications and safety requirements.
Step 4: Final Installation
Once the concrete footings had properly cured, we reinstalled the safety barriers in their original locations, ensuring all components were securely anchored and aligned.
The Result
The warehouse guard rail safety barriers in Syosset, NY were fully restored to their intended functionality. The new concrete footings and steel channels now provide improved resistance to impact, ensuring a safer working environment for warehouse personnel and equipment. The project was completed on time and met all structural and safety standards.
Why Choose Zavza Seal?
At Zavza Seal, we specialize in warehouse guard rail repair in Syosset and across Long Island, delivering reliable, long-lasting solutions for commercial facilities. Our expertise in concrete footing repair, steel welding, and safety barrier installation ensures your property remains protected and compliant with safety regulations.
Contact us today for a consultation and keep your facility safe and secure.