Case Study: Replacing Old Steel Beams in a North Jersey Warehouse

Case Study: Replacing Old Steel Beams in a North Jersey Warehouse

When warehouse owners discover that their structural steel beams are aging or no longer safe, they need more than patchwork repairs—they need a professional team that can replace old beams with new steel quickly, safely, and with minimal disruption to business.

Recently, our team at Structural Welders was called in to handle exactly that for a warehouse in North Jersey.

The Challenge

The warehouse was built over 40 years ago. Over time, several steel beams had:

• Developed corrosion from roof leaks,

• Lost load capacity due to added storage racks, and

• No longer met modern safety codes.

The building owners needed the beams replaced before expanding operations, but shutting down the warehouse for weeks wasn’t an option.

Our Solution

We designed a step-by-step plan that combined engineering precision with practical fieldwork:

1. Structural Assessment

   
   

   • Inspected all beams and columns.

   • Calculated load requirements for new racks and machinery.

   • Determined the proper W-beam sizes for replacement.

2. 
   

3. Temporary Shoring

   
   

   • Installed heavy-duty shoring towers to hold the roof and joists safely during the swap.

   • Ensured warehouse activity could continue in non-work zones.

4. 
   

5. Removal of Old Beams

   
   

   • Used cutting torches and mechanical unbolting.

   • Safely rigged beams for removal with forklifts and a small mobile crane.

6. 
   

7. Installation of New Beams

   
   

   • Positioned and set the new ASTM A992 structural beams.

   • Welded and bolted connections to tie them into the existing framework.

   • Added protective primer and paint to guard against future corrosion.

8. 
   

9. Final Quality Check

   
   

   • Every weld inspected and tested.

   • Load test performed to confirm capacity.

10. 
    

The Results

• Stronger Structure: New beams now exceed today’s load requirements.

• Minimal Downtime: Work zones were carefully managed, so warehouse operations continued throughout the project.

• Long-Term Durability: Protective coatings ensure decades of safe use.

The client now has a warehouse ready for expansion, safe for workers, and compliant with building codes.

Key Takeaways

This project highlights why steel structures services are critical for warehouses:

• Old beams can be dangerous and costly to ignore.

• Professional steel welding services ensure replacements are done safely and efficiently.

• With the right planning, even large-scale structural work can be completed without shutting down operations.

Contact Us

If your warehouse or commercial building needs steel beam replacement, trust the experts at Structural Welders.

📞 Call us today at 844-9-WELDER (844-993-5337)

🌐 Visit: www.structuralwelders.com