Bollard System With Rapid Replacement Features

Abstract

A bollard system includes a base structure with an elongated portion and an interface plate positioned proximate one end of the elongated portion. The elongated portion extends below a grade level with the interface plate above the grade level. A bollard structure has an elongated portion and an interface plate. The bollard structure interface plate is coupled with the base structure interface plate to form an interface for supporting the bollard structure elongated portion above the grade level. The bollard structure interface plate has a thickness that is less than the thickness of the base structure interface plate so the interface is skewed and the bollard structure absorbs damaging forces and protects the base structure.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 63/474,556 filed Aug. 24, 2022 (pending), and U.S. Provisional Patent Application Ser. No. 63/493,114 filed Mar. 30, 2024 (pending), the disclosures of which are incorporated by reference herein.

TECHNICAL FIELD

This application is directed to protection structures and systems, commonly referred to as bollards, and is particularly directed to a bollard system for protecting structures and facilities from vehicle impact.

BACKGROUND OF THE INVENTION

Bollard structures and systems are used extensively as safety barriers to prevent damage to property, equipment and other facilities from vehicle impacts. The bollard structures or bollards are often placed in parking lots of an establishment in various locations proximate to the structures to be protected. Bollards are generally upstanding metal structures that are set into concrete around the area or structure to be protected. A section of an elongated bollard is anchored in the ground, such as in concrete, and another section sticks above the ground. Bollards are usually 4-8 inches in diameter with a suitable length to be anchored in 1-2 yards of concrete and present a bollard structure that extends 42-48 inches above grade level of the ground or pavement. Single bollards may be used or dual bollard systems having two upright bollards and a cross bar section are also generally common configurations.

Bollards are used in commercial, public and even some private settings to prevent structure and property damage that may occur from a vehicle impact or accident. For example, one common implementation of bollards and bollard systems is in the protection of fuel pumps around gas stations and truck stops. As may be appreciated, an accidental impact of a fuel pump from a wayward car or truck can create significant damage to the pump or worse if the flammable fuel were to escape. Accordingly, bollards are often used around fuel pumps as well as around buildings or other areas where vehicles are operating and moving. As such, the bollards will often serve their intended purpose and will be hit and/or damaged in use by moving vehicles.

When bollards are catastrophically damaged from vehicle impact, they usually are bent significantly or shear at the fulcrum of the bollard, which is at grade level in the concrete base or setting. This is because the force of impact from a vehicle generally pushes the bollard against the fulcrum point of the concrete at grade level. This is effectively where the bollard hinges. This has been observed numerous times during replacement and field tests. Such damage will usually require replacement of the entire bollard.

The replacement process is a cumbersome, lengthy and often expensive process. Bollard replacement requires extensive excavation of one to two yards of concrete and pavement to remove the damaged bollard. When the new replacement bollard is installed, new concrete is poured with reinforcement bars and the replacement bollard. This is a minimal two-day process generally and requires cordoning off access to the bollard and area of repair. The replacement work requires digging and removal of the damaged bollard and concrete, staging of equipment, and a two day cure period for the newly poured concrete.

Often, the information of the repair site for the installer is also not complete. The site might be remote to the installer and might only be viewed by photos to develop the quote for the replacement. No knowledge of traffic patterns or vehicle traffic volume may be known, so the efficiency and the cost effectiveness of the repair installation is based on past experience. Travel and mobilization of supplies and equipment to the site must be included in the overall cost. Furthermore, local concrete suppliers must be sought. Minimum order costs must be included. Another variable that is never identifiable is weather delays. Extra days in a hotel/motel will further directly affect the installer's and customer's costs.

The cordoned work area for the repair will cause traffic congestion in commercial facilities and restrict access to those revenue sources, such as fuel pumps, for a minimum period of two days. Additionally, conducting work in an active traffic area affects both installation efficiency and also poses a safety risk to both installers and facility customers. When a closure involves an entity linked to a national truck stop franchise, where a fuel dispenser is placed out of service for two days, the loss of revenue rapidly becomes significant. A typical existing bollard replacement might directly cost 3-5 thousand dollars. However, the truck stop's affected fuel pump is typically closed for two days during bollard replacement. The pumps normally are open 24 hours per day. The fuel pumps average dispensing 500 gallons per hour for a 24 hour total of 12,000 gallons. This equates to tens of thousands of dollars per day of lost revenue. With larger truck stop chains that might average 4-5 bollard replacement projects per week, a 52 week period will equate to a lost revenue total of over 20 million dollars.

Accordingly, there is a need for an improved bollard system. Specifically, there is a need for a bollard system that provides the necessary protection and similar shear strength from vehicle impact that is currently available, but which is more cost effective to install and then repair. There is a need for an improved bollard system that can be repaired in a time frame shorter than a couple of days and that may eliminate the need for breaking up old concrete and pouring and curing new concrete.

SUMMARY OF THE INVENTION

A bollard system includes a base structure having an elongated portion and an interface plate positioned proximate one end of the elongated portion. The elongated portion is configured to extend below a grade level to maintain the interface plate above the grade level. A bollard structure has an elongated portion and an interface plate. The bollard structure interface plate is configured to be coupled with the base structure interface plate to form an interface for supporting the bollard structure elongated portion above the grade level. The bollard structure interface plate has a thickness that is less than the thickness of the base structure interface plate so the interface is skewed and the bollard structure absorbs damaging forces to the bollard structure and protects the base structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross sectional view of the bollard system in accordance with an embodiment of the invention.

FIG. 2 is a cross sectional view of the bollard system along the lines 2-2 of FIG. 1.

FIG. 3 is an enlarged cross sectional view of the bollard system in accordance with an embodiment of the invention.

FIG. 4 is a cross sectional view of the bollard system in accordance with another embodiment of the invention.

FIG. 5 is a cross sectional view of the bollard system along the lines 5-5 of FIG. 4.

FIG. 6 is a cross sectional view of the bollard system in accordance with an embodiment of the invention illustrating a guard element.

FIG. 7 is an enlarged cross sectional view of the bollard system in accordance with an embodiment of the invention of FIG. 6.

It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various features illustrative of the basic principles of the invention. The specific design features of the sequence of operations as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes of various illustrated components, will be determined in part by the particular intended application and use environment. Certain features of the illustrated embodiments have been enlarged or distorted relative to others to facilitate visualization and clear understanding. In particular, thin features may be thickened, for example, for clarity or illustration.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The present invention presents a bollard and bollard system that reduces repair times and cost. It incorporates multiple sections or structures with a unique interface that ensures that the bollard system absorbs damage but may be more easily and readily repaired in significantly less time than existing bollard systems if the damage is catastrophic. In that way, facility owners and operators, such as owners in the truck stop industry and other commercial users avoid unnecessary large financial impacts when a bollard must be replaced. The inventive bollard system is applicable to any commercial, industrial, governmental, or private application that uses M3P1 type bollards. The bollard system of the present invention can replace a bollard in less than 30 minutes with no necessary excavation of concrete or the pouring of new concrete. This minimizes cost, revenue loss, and safety risks to the business.

In test installations, the bollard system was impact tested using a 25,000 lbs. truck at 10-15 feet and 15 miles per hour. Several destructive iterations of testing were conducted. The tests were recorded for establishing that the forces causing replacement deformation for the bollard system was equal to or greater than those that caused catastrophic damage and replacement with the standard grade level installation of an M3P1 bollard that is inset in concrete. The present invention and its unique design surpasses the shear strength of the typical concrete embedded bollard. The other features of the bollard system makes the bollard easily interchangeable and replaceable with minimal tools, such as a wrench. The bollard system eliminates costly excavation revenue stream loss to businesses due to closures. The system is also safer to install since exposure to moving traffic is greatly reduced from a time standpoint. The inventive bollard system thus provides cost savings and time savings, with no reduction in shear strength or in quality of safety. Furthermore, the bollard system may be repaired by a non-technical or non-skilled person.

FIG. 1 is a cross-sectional view of the bollard system 10 in accordance with one embodiment of the invention. The bollard system 10 incorporates a below grade structure and an above grade structure. In accordance with one feature of the invention, because of the unique design and operation of bollard system 10, when significant damage is done to the above grade structure, it can be removed and replaced while the below grade structure remains intact. In that way, there is no requirement to dig up concrete in order to remove the below grade structure or to pour new concrete for a new bollard.

Generally, a traditional bollard is an elongated and unitary element wherein a section of the bollard is set in concrete and another section remains above the concrete in order to prevent vehicle damage to a structure, such as a fuel pump or building. When the exposed section is damaged, the entire bollard or pieces thereof have to be removed, thus requiring digging up concrete and installing a new bollard.

Referring again to FIG. 1, the bollard system 10 of the invention includes an above grade bollard or bollard structure 12 and a below grade and separate base structure 14. The bollard structure 12 and base structure 14 are coupled together through a unique interface 16 as described herein. Specifically, referring to FIGS. 2 and 3, interface 16 incorporates a unique combination of interface plates for ensuring that catastrophic forces encountered by bollard structure 12 are translated appropriately and primarily to the bollard structure 12 with little or minimal damage to the base structure 14. Referring to FIG. 3, the bollard structure 12 incorporates an elongated portion 13 and an interface plate 20 that is positioned proximate to or at one end of the elongated portion 13. The interface plate 20 is positioned in a plane that is generally perpendicular to the longitudinal axis of the elongated portion 13. The base structure has an elongated portion 15 and an interface plate 22 positioned proximate one end of the elongated portion. The elongated portion 15 is configured to extend below a grade level to maintain the interface plate 22 above grade level. The interface plate 22 is positioned in a plane that is generally perpendicular to the longitudinal axis of the elongated portion 15.

The interface plate 20 secured to the bollard structure is coupled with the interface plate 22 secured to the base structure 14 to complete the system. The interface plates 20, 22 have openings 26 through the plates that are positioned around the circumference of the interface plates 20, 22 and are dimensioned and configured for being aligned and receiving fasteners, such as bolts 28 for holding together opposing faces 30, 32 of the interface 16 of the bollard system 10 that is installed. For example, suitable bolts might be grade 8, ⅝ inch bolts having a length of around 3 inches to pass through the opposing plates 20, 22 and be secured with suitable similar ⅝ inch diameter nuts 36 and washers 38 as shown in FIG. 3. Generally the elongated portions 13, 15 of the bollard structure and base structure are configured to extend vertically above grade level and below grade level, respectively, and so the planes of the interface plates 20, 22 are generally oriented horizontally at the completed interface.

In accordance with one embodiment the invention, the bollard structure 12 and base structure 14 may be formed of a suitable metal. In one embodiment, schedule 40, A53 type F steel might be utilized, The elongated portions 13, 15 may have a diameter D₁ for the bollard structure and a diameter D₂ for the base structure that could be 4, 6, 8, 10 inches, for example. Generally, the diameter D₁ of the bollard structure will match the diameter D₂ of the base structure for a particular bollard system. However, there may be differences between the base structure diameter D₂ and the bollard structure diameter D₁ as long as the interface plates 20, 22 appropriately can be aligned for being secured together to create the inventive bollard system 10.

The interface plates 20, 22 may be made of steel, such as grade A36 steel. The plates 20, 22 may be generally circular in their shape as shown in FIGS. 2 and 5, to match the circular cross-sections of the elongated portion 13 of the bollard structure 12 and the elongated portion 15 of the base structure 14. They will generally have a diameter suitable for the diameter of the particular bollard structure or base structure. For example, the interface plates might have diameters from 10-16 inches depending on the size of the bollard structure and base structure. In one embodiment of the invention, an 11⅞ inch diameter circular steel plate, might be utilized, for example, for a 4 inch diameter or 6 inch diameter bollard system. The interface plates 20, 22 are secured to the bollard structure and base structure, such as by welding and are uniquely configured for providing protection for the base structure 14 upon a catastrophic vehicle impact to the bollard structure 12.

The interface 16, in accordance with the invention, provides a skewed interface that favors the base structure and protects the base structure from damage when a vehicle strikes the bollard structure. More specifically, the bollard structure interface plate 20 has a thickness that is less than the thickness of the base structure interface plate 22, so the bollard structure absorbs damaging forces to the bollard structure and protects the base structure for reuse. In one embodiment, the interface plate 20 associated with bollard structure 12, and that sits above generally the grade or ground level 40, has a thickness T₁ that is significantly less than the thickness T₂ of the interface plate 22 of the base structure. For example, in one embodiment, the thickness T₁ of the interface plate 20 is only 50% of the thickness T₂ of interface plate 22 of the base structure. In one particular embodiment, interface plate 22 might have a 1 inch thickness whereas interface plate 20 might have a ½ inch thickness. In accordance with the invention, the thickness T₁ may be reduced from 25% to 75% from the thickness T₂ and is preferably reduced by at least 50%, to ensure that catastrophic damage to bollard structure 12 is contained within the bollard structure and interface plate 20 rather than being transferred to base structure 14 through the interface plate 22. Containing the damage to bollard structure 12 and isolating the base structure 14 in accordance with the invention ensures that the repair of a damaged bollard system 10 can readily be achieved by replacing bollard structure 12.

Referring to FIG. 1, the bollard system may incorporate a bollard structure 12 with an elongated portion 13 that may have a number of different lengths to extend vertically to a particular height above grade level 40. For example, the bollard structure 12 elongated portion might be 42 inches, 48 inches, or 60 inches depending on the need of the installation. Generally, the elongated portion 15 of the base structure 14 may be about 36 inches to be inset into the concrete below grade level 40. To install the bollard systems 10 of the invention, the base structure 14 is positioned with the elongated portion 15 extending downwardly into a suitable hole 50 that may be dugout of existing ground or pavement 52. The base structure 14 is positioned in the hole 50. Other supporting structure, such as rebar 54 might by incorporated in the hole 50 such to structurally work with concrete 60 that is poured into the hole to support and secure the base portion. Rebar or other structures are not necessary and the base structure 14 may be set and secured just in the concrete 60. Once hole 50 of a suitable dimension has been excavated, the base structure 14 is positioned and fresh concrete is poured into the hole and allowed to set appropriately to support the base structure 14 so that interface plate 22 is above grade level 40 and is generally parallel to the plane of the grade or ground surface so that the attached bollard structure 12 will extend vertically.

The steel portion 15 of the base structure 14 might be set directly into concrete and secured. In an alternative embodiment of the invention, anti-corrosion measures might be taken with respect to base structure 14 where the elongated portion 15 it interfaces with concrete 60. To that end, an anti-corrosion collar or strip 62 may be incorporated around a section of the base structure 14 proximate to grade level 40. The anti-corrosion collar 62 may have a suitable height H that is appropriate for extending slightly above grade level 40 and below the grade level to provide corrosion resistance for water and other corrosive materials which may encounter the base structure at the grade level 40. One suitable material for such an anti-corrosion collar 62 is neoprene that may be around 0.187 inches thick.

Generally, the base structure is positioned in hole 50 so that the interface collar 22 is close to grade level but rests above the grade level 40 slightly for providing sufficient space between the interface plate 22 and the grade level. In that way, tools such as a wrench, may be used to tighten any nuts 36 or other fastener elements for securing the interface plates 20 and 22 together. For example, the base structure 14 may be positioned with the interface plate 22 around 2 inches above grade level or essentially is high enough to allow a wrench or other tool to be used to tighten the nuts 36 and thereby secure the bollard structure 12 with base structure 14. Once the base structure 14 is in place and concrete 60 has set within hole 50, the bollard structure 12 may be attached to the base structure. To that end, the interface plates 20 and 22 are aligned at faces 30, 32 so that the respective openings 26 therethrough are aligned and fasteners such as bolts 28 may be inserted to engage respective nuts 36. Generally, the bolts 28 will be inserted downwardly from the top of the interface plate 20 and into and through the interface plate 22 to engage the nuts 36 and washers 38 below interface plate 22. However, the bolts may also be inserted from interface plate 22 upwardly and through the interface plate 20. Once the bolts 28 are tightened appropriately with suitable nuts 36 and washers 38, the interface plates 20 and 22 cooperate to provide a strong yet damage absorbing interface 16 for the bollard structure 12.

As noted, any damage from catastrophic forces from a vehicle on the bollard structure 12 will generally be limited to the bollard structure 12 and its thinner interface plate 20. The bollard structure 12 and interface plate 20 absorb the forces and protect the base structure. To that end, if the bollard structure 12 needs to be replaced, the base structure 14 and interface plate 22 may remain in place and the bolts 28 can be removed so that the bollard structure 12 and interface plate 20 may be removed. Another bollard structure may then be attached to the existing base structure through an alignment with interface 22 and appropriate fasteners as disclosed herein. The bollard system 10 of the invention eliminates costly excavation costs and the revenue stream loss associated with the closure of certain areas, such as fuel pumps. The replacement procedure is more time efficient and safer since the exposure to moving traffic by installers is greatly reduced. The time to break up the concrete around the bollard is eliminated as the same base structure stays in position. This reduces a replacement procedure time from days to under an hour or less generally. Therefore, damaged bollards may be replaced without significant financial impacts to the establishment owner.

While FIGS. 1-3 illustrate a single bollard structure, FIGS. 4-5 illustrate an alternative bollard system 10a that incorporates two bollard structures 12a, each with an elongated portion 13 and a cross element 17 the couples the elongated portions 13. The bollard system 10a may be utilized to protect a wider area or element than the bollard system 10 of FIG. 1. The bollard system 10A may be installed and repaired similarly to bollard system 10 shown in FIG. 1. Accordingly, reference numerals are similar for common elements with respect to those utilized with the bollard system of FIG. 1.

In accordance with another feature of the invention, because the unique bollard system 10, 10A of the invention provides an interface 16 having interface plates 20, 22 that are wider than the bollard structures 12, 12a, other elements might be utilized to protect the interface 16 and protect people that are around the bollard system from being tripped or injured, such as by striking their ankles on the interface 16. To that end, as illustrated in FIGS. 6 and 7 a cover structure 70 may be utilized over the interface 16 to cover the interface plates 20, 22 as well as the bolts or other fasteners 28 and appropriate nuts and washers. Cover 70 might be formed of a suitable plastic material, such as PVC, which surrounds the bollard structures 12, 12a and may slide up and down on the elongated portions 13 thereof. The cover 70 may then be slid into position over the interface 16 when installation is complete. To that end, cover 70 might incorporate an opening 72 sufficient to receive the elongated portions 13 of the bollard structures 12, 12a as illustrated in FIG. 7. Once the cover 70 is in place, the interface 16 is covered, such as from the elements, and also as a protection against injury or damage from the wider interface 16 which will stick out from the bollard structure.

While the present invention has been illustrated by a description of various embodiments and while these embodiments have been described in some detail, it is not the intention of the inventors to restrict or in any way limit the scope of the appended claims to such detail. Thus, additional advantages and modifications will readily appear to those of ordinary skill in the art. The various features of the invention may be used alone or in any combination depending on the needs and preferences of the user.

Claims

1. A bollard system comprising:

a base structure having an elongated portion and an interface plate positioned proximate one end of the elongated portion, the elongated portion configured to extend below a grade level to maintain the interface plate above the grade level;

a bollard structure having an elongated portion and an interface plate, the bollard structure interface plate configured to be coupled with the base structure interface plate to form an interface for supporting the bollard structure elongated portion above the grade level; and

the bollard structure interface plate having a thickness that is less than the thickness of the base structure interface plate so the interface is skewed and the bollard structure absorbs damaging forces to the bollard structure and protects the base structure.

2. The bollard system of claim 1 wherein the bollard structure interface plate thickness is 25%-75% less than the thickness of the base structure interface plate for absorbing damaging forces to the bollard structure.

3. The bollard system of claim 2 wherein the bollard structure interface plate thickness is approximately 50% less than the thickness of the base structure interface plate for absorbing damaging forces to the bollard structure.

4. The bollard system of claim 1 wherein the base structure interface plate is approximately 1 inch in thickness.

5. The bollard system of claim 1 wherein the bollard structure interface plate is approximately 0.5 inches in thickness.

6. The bollard system of claim 1 wherein the bollard structure and base structure elongated portions are formed of metal and the respective interface plates are welded proximate an end of the respective elongated portion.

7. The bollard system of claim 1 further comprising a cover element, the cover element configured for covering the interface and respective interface plates of the base structure and bollard structure.

8. The bollard system of claim 1 further comprising an anti-corrosion collar configured for positioning around a section of the base structure elongated portion that is configured to extend below the grade level.

9. A bollard system comprising:

a plurality of base structures, each base structure having an elongated portion and an interface plate positioned proximate one end of the elongated portion, the respective elongated portions of the base structures configured to extend below a grade level to maintain the respective interface plate above the grade level;

a bollard structure having a plurality of elongated portions and a cross element coupling at least two of the plurality of elongated portions, an interface plate positioned proximate one end of each of the elongated portions;

the bollard structure interface plates configured to be coupled with the base structure interface plates to form a plurality of interfaces for supporting the bollard structure elongated portions and cross element above the grade level; and

the bollard structure interface plates having a thickness that is less than the thickness of the base structure interface plates so the interfaces are skewed and the bollard structure absorbs damaging forces to the bollard structure and protects the base structure.

10. The bollard system of claim 9 wherein the bollard structure interface plates thicknesses are approximately 25%-75% less than the thicknesses of the base structure interface plates for absorbing damaging forces to the bollard structure at the interface.

11. The bollard system of claim 10 wherein the bollard structure interface plate thicknesses are approximately 50% less than the thicknesses of the base structure interface plates for absorbing damaging forces to the bollard structure.

12. The bollard system of claim 9 wherein the base structure interface plates are approximately 1 inch in thickness.

13. The bollard system of claim 9 wherein the bollard structure interface plates are approximately 0.5 inches in thickness.

14. The bollard system of claim 9 wherein the bollard structure and base structure elongated portions are formed of metal and the respective interface plates are welded proximate an end of the respective elongated portion.

15. The bollard system of claim 9 further comprising at least one cover element, the cover element configured for covering at least one of the interfaces and respective interface plates of the base structure and bollard structure.

16. The bollard system of claim 9 further comprising an anti-corrosion collar configured for positioning around a section of at least one of the base structure elongated portions that is configured to extend below the grade level.