How Bollards Are Made: Materials, Manufacturing and Strength

Security bollards may look relatively simple from the outside, but there is considerably more to their construction than a length of steel fixed into the ground. The material, wall thickness, locking system, protective finish, below-ground components and installation all influence how the finished bollard performs.

Different bollards are also designed for very different jobs. A lightweight flexible post used to guide traffic is not intended to provide the same level of physical security as a substantial steel bollard installed into a prepared foundation.

Understanding how bollards are manufactured makes it easier to compare products and decide what is suitable for a driveway, parking area or commercial property.

What Are Security Bollards Made From?

Security bollards can be manufactured from several materials, including mild steel, stainless steel, concrete and various plastics or polymers.

The right material depends largely on what the bollard is expected to do.

Common materials include:

• Mild steel for strong security and access-control bollards
• Stainless steel where strength and appearance are both important
• Concrete for permanent traffic separation and public spaces
• Flexible plastics and polymers for traffic guidance and visibility

For driveway and commercial security applications, steel is one of the most common choices because it can be manufactured in different diameters and thicknesses, combined with secure locking mechanisms and installed into substantial ground housings.

How Are Steel Bollards Made?

A steel security bollard is generally manufactured through several stages, beginning with the product specification and ending with the protective finish and final assembly.

The exact process varies by manufacturer and bollard design, but typically involves:

1. Designing the bollard and determining its dimensions
2. Cutting steel tube and plate to size
3. Machining openings and fixing points
4. Welding structural components together
5. Installing locks, hinges or guide mechanisms
6. Preparing the steel for corrosion protection
7. Applying galvanising, powder coating or another finish
8. Inspecting and assembling the completed product

Moving bollards require additional components because the post needs to operate repeatedly without excessive movement, sticking or misalignment.

1. The Bollard Starts With A Product Specification

Before any steel is cut, the manufacturer needs to establish exactly what is being produced.

The specification can include:

• The overall length of the bollard
• The height above ground when raised
• The post diameter or profile
• The thickness of the steel
• The locking arrangement
• The ground housing or fixing method
• The required surface finish
• Whether the bollard is fixed, removable or telescopic

A fixed bollard has relatively few moving components. A telescopic bollard is more involved because the design also needs to accommodate the housing beneath the driveway, the movement of the post and the locking mechanism.

2. Steel Tube And Plate Are Cut To Size

The main post normally begins as steel tube manufactured to the diameter, profile and wall thickness required by the design.

Steel plate may also be needed for components such as base plates, lids, housings and internal supports.

These materials are cut to the dimensions specified for the particular bollard.

Precision matters. If components are cut or aligned poorly, it can affect how the completed bollard sits in its housing, how the lock engages and how smoothly a moving bollard operates.

3. Additional Components Are Formed And Machined

Depending on the design, the steel may then be drilled, machined or formed to accommodate other parts of the bollard.

These can include:

• Locking mechanisms
• Base plates
• Hinge assemblies
• Internal guides
• Lifting components
• Ground housings
• Drainage provisions

Telescopic and removable bollards generally require more components than a simple fixed post because the bollard needs to move while remaining stable once secured.

4. The Bollard Is Welded And Assembled

Individual steel components are then joined together, often using welding.

Depending on the bollard, this may involve joining:

• The main steel post
• Internal reinforcement
• Base plates
• Locking points
• Guide components
• Housings
• Structural supports

The position and quality of these joints matter because the bollard needs to function as a complete assembly rather than simply as a hollow steel tube.

Moving products also need enough precision to allow repeated operation without the post becoming excessively loose or difficult to move.

What Makes A Security Bollard Strong?

The material is important, but steel alone does not determine how strong a security bollard will be.

Several aspects of the construction work together, including:

• The thickness of the steel wall
• The diameter or overall profile of the post
• The type and grade of material
• Any internal reinforcement
• The construction of welded joints
• The design of the locking mechanism
• The below-ground housing or ground socket
• The foundation supporting the bollard

A larger diameter or thicker-walled post will generally feel more substantial, but the finished installation still depends on how that post is secured into the ground.

A strong-looking bollard sitting in an unsuitable foundation may not perform as intended.

Does Steel Thickness Matter?

Yes. The wall thickness, sometimes referred to as the gauge of the post, is one of the factors affecting the construction of a steel bollard.

Two bollards may appear similar in photographs while using steel of different thicknesses internally.

Heavier-duty products may also incorporate additional reinforcement within the post rather than relying solely on the outer steel tube.

Thickness should still be considered alongside diameter, locking arrangement and the way the bollard is installed rather than treated as a single measure of security.

Why Does Bollard Diameter Matter?

The diameter of a round bollard affects both its appearance and construction.

Domestic products may use a relatively slim post that provides a useful physical barrier without dominating the driveway, while heavier-duty security bollards can use larger diameter sections and thicker steel.

The correct choice depends on the intended application rather than simply selecting the largest available product.

What Is Mild Steel?

Mild steel is commonly used for security bollards because it can be cut, formed and welded into strong structural components.

It can also be manufactured in a wide range of diameters and thicknesses, making it suitable for anything from domestic driveway bollards to heavier commercial security posts.

Because ordinary carbon steel can corrode when repeatedly exposed to moisture, outdoor products usually require a protective finish.

How Are Steel Bollards Protected Against Rust?

Outdoor bollards spend their entire working life exposed to rain, moisture, road dirt and changing temperatures, so corrosion protection is an important part of their manufacture.

Common methods include galvanising and powder coating.

Galvanised Steel Bollards

Hot-dip galvanising protects prepared steel by coating it in zinc.

The process creates a protective layer over the underlying steel, helping it withstand outdoor exposure.

Galvanised steel typically has a silver or grey appearance. Slight differences in the appearance of the surface can occur naturally as part of the galvanising process.

Powder-Coated Bollards

Powder coating allows a steel bollard to be given a coloured finish while adding another protective layer to the surface.

A dry powder is applied to prepared metal and then cured to produce a continuous coating.

This makes it possible to offer security bollards in colours such as:

• Black
• Dark grey
• White
• Yellow
• Other selected finishes

Colour can be chosen for appearance, visibility or both. Black bollards can sit discreetly on a residential driveway, while brighter finishes may be preferable around busy commercial areas where drivers need to notice the posts easily.

How Are Stainless Steel Bollards Made?

Stainless steel bollards go through many of the same cutting, forming, welding and assembly stages as other steel products.

The difference is the material itself.

Stainless steel contains alloying elements that improve corrosion resistance, which can make it attractive where the bollard will remain visible outside a home, office or commercial development.

The finished surface may be:

• Brushed
• Satin finished
• Polished

Stainless steel is resistant to corrosion rather than completely maintenance free. Occasional cleaning can help maintain its appearance, particularly where the post is exposed to road deposits, dirt and pollution.

Mild Steel Or Stainless Steel Bollards: Which Is Better?

Neither material is automatically the right choice for every installation.

Mild steel security bollards can provide substantial construction and can be galvanised or powder coated to protect the surface.

Stainless steel is often chosen where a more premium visible finish is important alongside security.

The decision may therefore depend on:

• The required level of physical security
• The appearance of the property
• The installation environment
• Available bollard specifications
• Budget

You can compare the different materials and configurations within the Northern Bollards range of security bollards.

How Are Telescopic Bollards Made?

A telescopic bollard is more complex than a fixed post because much of the product sits below the driveway when access is open.

The visible steel post forms only part of the complete system.

A typical telescopic bollard can include:

• The main rising security post
• A below-ground steel casing
• A locking top or mechanism
• Internal guides
• A surface lid or plate
• Structural base components
• Drainage provision around the installation

When access is required, the post moves down into the outer housing. It can then be raised and secured again when the driveway needs protecting.

The relationship between the post and housing needs to be carefully controlled so the bollard remains aligned during operation.

Some heavier products can also include mechanisms designed to make lifting the post easier.

Northern Bollards offers a range of telescopic security bollards for domestic and heavier-duty installations.

How Are Removable Bollards Made?

A removable bollard consists of a separate security post and a socket installed into the ground.

The post needs to fit securely into the socket when locked while remaining straightforward to release when access is required.

Some designs include a cover for the ground opening when the post has been removed.

Unlike a telescopic bollard, the post does not remain within the driveway. It needs to be lifted completely out and stored elsewhere.

How Are Fold-Down Bollards Made?

Fold-down bollards incorporate a hinge assembly close to ground level.

The post locks vertically when access needs to be restricted and pivots down towards the driveway when the entrance is opened.

The hinge needs to withstand repeated operation while maintaining sufficient stability when the bollard is upright.

Its base also needs to be installed onto an appropriate surface or foundation.

How Are Fixed Bollards Made?

Fixed steel bollards are generally simpler mechanically because they do not need locks, hinges or retracting mechanisms.

The main consideration is creating a strong post and securing it appropriately into the ground.

They can be used where permanent vehicle restriction is required, such as:

• Beside buildings
• Around equipment
• Along pedestrian areas
• At permanently closed vehicle routes
• Around commercial boundaries

Are Concrete Bollards Made Differently?

Yes. Concrete bollards are generally produced using moulds rather than fabricated from tube and plate.

Concrete is prepared and poured into the required form, sometimes around internal reinforcement depending on the product design.

The material then needs time to cure before the bollard is finished and installed.

Because concrete bollards are heavy and generally permanent, they are commonly associated with public spaces, landscaping and permanent traffic separation rather than frequently opened residential driveways.

What About Plastic And Flexible Bollards?

Plastic or flexible bollards are normally manufactured using moulding processes.

They may use bright colours and reflective bands to improve visibility and can be useful for:

• Traffic guidance
• Marking lanes
• Highlighting hazards
• Separating areas visually

They should not be confused with substantial steel security bollards.

A flexible post designed to bend when struck performs a fundamentally different job from a steel post intended to physically restrict vehicle access.

Does The Lock Matter As Much As The Steel?

The locking mechanism is an important part of any movable security bollard.

A substantial steel post is of limited value if it cannot remain securely locked in its raised position.

The lock also needs to remain practical to operate in an outdoor environment where the bollard may be exposed to rain, dirt and frequent use.

Depending on the product, multiple bollards may also be available keyed alike so that the same key can operate several posts.

This can be particularly convenient where two or more bollards are installed across the same driveway or commercial entrance.

Does Bollard Installation Affect Strength?

Yes. Manufacturing the bollard is only part of the overall security system.

The finished product also depends on what happens once it reaches the property.

Installation can involve:

• Excavating the driveway
• Preparing a suitable foundation
• Positioning the bollard accurately
• Providing appropriate drainage
• Checking surrounding ground conditions
• Reinstating the driveway surface

A correctly manufactured product installed badly may not perform or operate as intended.

Why Are Foundations Important?

A security bollard transfers loads into the ground around it.

The foundation or below-ground housing therefore plays an important role in keeping the post stable.

The required installation will vary according to the bollard, ground conditions and driveway construction.

Concrete, tarmac and block paving can each require a different approach to excavation and reinstatement.

Why Is Drainage Important?

Drainage is particularly relevant for telescopic products because the bollard retracts below ground.

Water, dirt and debris collecting around the housing can interfere with moving components if the installation is not designed and maintained appropriately.

This is why the area below the attractive visible post matters just as much as the section seen above the driveway.

Why Do Underground Services Matter?

A below-ground bollard cannot simply be installed anywhere there appears to be enough space on the surface.

The area beneath a driveway can contain:

• Electricity cables
• Gas supplies
• Water pipes
• Drainage
• Telephone and broadband lines
• EV charging cables

These can influence where excavation is possible and may require the proposed position to be changed.

Are All Heavy-Duty Bollards Crash Rated?

No. Terms such as “heavy duty”, “security bollard” and “steel bollard” do not automatically mean that a product has undergone recognised vehicle-impact testing.

Crash-rated security barriers are assessed under defined testing conditions using specific vehicle weights, speeds and impact arrangements.

A standard security bollard can still create a substantial physical obstacle for access control and vehicle protection, but it should not be assumed to provide a particular level of impact resistance without supporting evidence for that specific product.

What Is The Difference Between A Security Bollard And A Traffic Bollard?

The difference is primarily the job each product is designed to perform.

A traffic bollard may be intended to:

• Guide drivers
• Improve visibility
• Mark a lane
• Highlight a boundary

A security bollard is intended to create a more substantial physical restriction to vehicle movement.

Two products may therefore both be called bollards while having very different construction and performance.

What Should You Look For When Comparing Bollards?

Rather than comparing products on appearance alone, look at the complete specification.

Useful details can include:

• Post diameter
• Steel thickness
• Material
• Internal reinforcement
• Locking mechanism
• Ground housing construction
• Protective finish
• Height above ground
• Method of operation
• Installation requirements

The right specification will depend on whether the bollard is protecting a domestic driveway, controlling parking or providing a heavier-duty barrier around commercial premises.

How Are Security Bollards Made? Frequently Asked Questions

What Metal Are Security Bollards Made From?

Many security bollards are manufactured from mild steel or stainless steel. The material, thickness, diameter and overall design vary according to the intended application.

Why Are Steel Bollards Galvanised?

Galvanising applies a protective zinc coating to steel, helping protect the underlying material from corrosion when used outdoors.

What Is A Powder-Coated Bollard?

A powder-coated bollard has a coloured protective finish applied to prepared metal and cured to form a continuous coating. It allows steel bollards to be supplied in colours such as black, grey, white or yellow.

Is Stainless Steel Better Than Mild Steel?

They offer different benefits. Stainless steel provides good corrosion resistance and a premium visible finish, while mild steel can be used to manufacture substantial security posts and protected using galvanising or powder coating.

What Makes A Bollard Heavy Duty?

Heavy-duty construction can involve a larger post diameter, thicker steel, internal reinforcement, a substantial ground housing and a robust locking arrangement. The installation and foundation are also important.

Are Security Bollards Solid Steel?

Many security bollards are manufactured from thick-walled steel tube rather than being completely solid. The exact construction depends on the individual product and may also incorporate internal reinforcement.

How Do Telescopic Bollards Go Into The Ground?

The visible post retracts into an outer housing installed beneath the driveway. Internal components keep it aligned as it moves between its raised and lowered positions.

Are All Steel Bollards Impact Rated?

No. A steel bollard should only be described as impact or crash rated where the particular product has supporting evidence from recognised vehicle-impact testing.

Does A Thicker Bollard Mean Better Security?

Steel thickness is one important factor, but it should be considered alongside the post diameter, reinforcement, lock, ground housing, foundation and installation.

Choosing A Well-Made Security Bollard

What appears above the driveway is only part of a security bollard. The material, steel thickness, internal construction, locking system, protective finish, ground housing and installation all contribute to the finished result.

This is why two bollards that look broadly similar can have very different specifications.

The best product will depend on where it is being installed, how often it will be operated and what level of vehicle control is required.

If you need help comparing products or choosing a suitable security bollard for your driveway, parking area or commercial property, contact Northern Bollards to discuss the proposed installation.