Questions & answers about assessing and fixing rust damage to steel posts or columns.

This article series explains how to evaluate rust damage to steel columns, posts, adjustable columns in homes, and we illustrate the difference between harmless cosmetic or surface rust and serious exfoliating rust, splitting columns and risk of building or floor collapse.

FAQS: How to Evaluate & Fix Rusted Steel Columns / Posts

These questions and answers about rusty or damaged Lally columns or other steel columns and posts appeared originally at x - be sure to see the diagnostic and repair advice given there.

Watch out: Some of these residential column or post defects are dangerous and risk collapse.

This article describes a structural column defects in residential buildings. Larger structures using supporting columns and piers certainly require additional professional design from a civil or structural engineer or similar design professional.

[Click to enlarge any image]

On 2019-01-02 by (mod) - 4 repair options for a rusty steel structural column

Rob

I agree with your plan of action provided the rust damage has left most of the original steel on the square column in your photo (shown above).

If you can poke a screwdriver through the rusty post base then your options are

0. Temporarily support the structure above, then

1. Replace the entire steel column, installing a pier to get the steel above ground.

This is the best and most-durable repair. The new pier, when cast, will include an appropriate connector bolt or bracket to secure the post bottom.

2. Column bottom cut + new pier: similar to option 1, but just cut off the bottom of the post at a height that will let you connect it to a new pier poured in place up to the post bottom and above ground.

3. Cut off and have a welder weld-on a new post base - how old is this post and how old is the home? Maybe this is not worth the trouble, and maybe it'd cost as much (to get a welder on site) as just replacing the whole post

4. Jackleg: fill hollow column with concrete: If the rust hole you made with our screwdriver is limited in size you could do what my dad called a "jackleg" repair - i.e. creative and amateur but that might work: drill a hole about 24" above ground, big enough to pour cement mix into the hollow post, and fill it up, engaging in the fantasy that the concrete core will help prevent a calamitous collapse.

I've seen all four of these approaches - IMO #1 or #2 are the best options.

On 2019-01-02 by Rob

Thanks for some great observations on previous posts - very informative. I have what appears to be a hollow support column holding up the corner of the roof, and it is routinely exposed to water, as it is an outdoor structure (photos enclosed).

Exfoliating rust has appeared 1-2" above paver grade, so I took out the pavers to find more rust below. (This is a Florida installation about 5 miles from the ocean as the crow flies.)

Based on your other recommendations, a good course of action seems to be to scrape and wire-brush the flaking rust off first, then seal it with a rust inhibiting paint, and after drying, maybe build a 1"-thick concrete collar around it.

It will ALWAYS be exposed to water based on its outdoor location. What are your thoughts?

On 2018-11-07 by (mod) - steel column in which the concrete is exposed and steel is missing: unsafe

If the concrete fill in a Lally coumn is exposed the column is damaged and lacks bending resistance. Such should be replaced.

When a steel column has split or when it is rusted such that the rust is flaking off in thick exfoliating chunks exposing the concrete inside the column, then the column is unreliable and potentially unsafe: it should be replaced.

On 2018-11-07 by Jim

Closing shortly on a 1961 built home one mile from the Jersey shore. Inspection revealed all (5) lally columns in basement and (1) in two-car garage has deterioration in spots all over the steel outer casing.

Home inspector called for contractor to further inspect and/or repair. Town building inspector said issue is cosmetic and that concrete is intact. Unfinished basement seems to be dry.

No real rust at base. Is this okay?

Don't want to needlessly replace. But unsure how to prevent further deterioration.

Can just dampness and humidity do this over time? Thanks

On 2018-10-16 by (mod) - renter needs help if building is unsafe

If you have pointed out your landlord in writing that there is a concern for possibles catastrophic structural collapse and the landlord simply ignores you you may have no choice but to get outside help.

That maybe your local building department or if your city has a renter's protection agency you might start there.

Watch out: I can't see enough in your photo, BUT If there are actual signs of collapsing posts or structural movement - gaps between floors and walls, for example, then the building may be unsafe and an immediate hazard.

On 2018-10-15 by Concerned Renter

I am a renter on the top floor of a two family home.

I have brought the state of the rusted lally posts in our basement to the attention of the landlord.

He doesn’t seem to be concerned as it’s been over 2 months and he’s not sent anyone to address them. Four of the six supporting the main beam are significantly rusted from top to bottom with 1/2 inch deep fissures in some parts.

My question is, if the posts have concrete in them, how serious and time sensitive is this issue?

If it needs to be addressed immediately, and he continues to ignore, can I call a building inspector or someone from a town level that could motivate him to fix this?
Thanks
CR

Question: what do you think of this rusty Lally Column?

2018/05/17

Was wondering your opinion about this Crawlspace lally column -

The metal on the column was all rusted. However, the concrete within was solid. I tapped the column with a screwdriver.

Did not notice any deflection by the beam. - Anonymous by private email

Reply:

Starting at COLUMNS & POSTS, DEFECTS you'll see examples of collapses that can occur. I have added your photo here on our FAQs page and include and our conversation to invite further comment.

Still, without its surrounding steel the column no longer can reliably function as intended - what prevents concrete fill from crushing is the surrounding steel column (and of course the column being originally stronger than the minimum needed).

Because the bottom of the column is badly split exposing concrete, The column in your photo should be replaced.

The concrete core may help prevent a direct downwards collapse, but with the steel lost the column has no longer a mechanical connection to its pier and has lost its bending resistance.

In New Jersey that may not be an immediate catastrophe. In an earthquake zone it would invite a disaster.

Furthermore, rust like this - exfoliating rust - tells us that there was a history of flooding in that area - a problem that needs to be investigated and fixed. Below: a closeup of the collapsing bottom of this Lally Column.

Watch out: Over a flooded crawl space I would expect that fiberglass insulation to be mold-contaminated.

See FIBERGLASS INSULATION MOLD

Watch out: also, we sometimes find that a wet basement or crawl space has sent moisture up through the rest of the building, even so far as to contribute to an attic mold or condensation problem.

...

Continue reading at COLUMN / POST RUST DAMAGE or select a topic from the closely-related articles below, or see the complete ARTICLE INDEX.

Or see these

Recommended Articles

• BASEMENT LEAKS, INSPECT FOR
• COLUMNS & POSTS, DEFECTS
  • TELEPOST vs PERMANENT COLUMNS
  • COLUMN TOP & BOTTOM CONNECTIONS
  • COLUMN LOCATION ERRORS
  • COLUMN BENDING FAILURES - EARTHQUAKE
  • COLUMN / POST MISSING
  • COLUMN / POST RUST DAMAGE
  • PIPES USED as POSTS?
  • PIER MISSING SETTLED
• FLOOD DAMAGE TO FOUNDATIONS
• SETTLEMENT CRACKS in SLABS

Suggested citation for this web page

COLUMN / POST RUST DAMAGE FAQs at InspectApedia.com - online encyclopedia of building & environmental inspection, testing, diagnosis, repair, & problem prevention advice.

Or see this

INDEX to RELATED ARTICLES: ARTICLE INDEX to BUILDING STRUCTURES

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