In 2019, the Miami-Dade County Department of Transportation and Public Works (DTPW) initiated a significant three-phase acoustical barrier replacement program aimed at improving quality of life for residents. The project, which had an $82 million budget, was launched due to the deteriorating condition of the old acoustical concrete barriers that posed a threat to citizens and the surrounding environment. Phases 1 and 2 were successfully completed, involving the removal of the old barriers.

On January 4, 2021, DTPW commenced Phase 3 of the program, focusing on replacing the acoustical barriers in areas where the old panels were removed. The new acoustical barriers were designed to mitigate the noise produced by passing trains and prevent it from affecting nearby properties. Key components of the new acoustical barrier system included steel t-beams that served as the backbone of the system and connected the panels to the Metrorail infrastructure.

The customer was looking for a coating protection system that would provide durability, last long into the future and protect against hurricane force winds up to 180 mph. One solution stood above the rest: hot-dip galvanizing.

Choosing to galvanize the t-beams in the project made logistically most sense compared to various paint methods. However, there were challenges that required the galvanizer and customer to partner together throughout the course of the project.

The project required a production rate of 400 units per week, which was significantly higher than standard galvanizing processes. This increased production rate necessitated efficient handling and processing of the t-beams to meet the project's timeline. Secondly, the “T” shape of the beams made them difficult to stack and transport. A customized palletizing method had to be developed to accommodate this design, ensuring the T-beams were properly processed during galvanizing. Lastly, the t-beams needed to be returned to the fabricator in the same method they were received for final processing to avoid additional time and costs associated with restacking. The customer was pleased with the the galvanizer during this process, stating, “We could not have met the demanding schedule of the project without a true partnership of the galvanizer.”

To address these challenges, various adaptations were implemented to keep the project moving forward. A unique palletizing method was developed by the fabricator to efficiently handle the flat t-beams during galvanizing. This approach facilitated the processing of a high volume of t-beams while maintaining quality and consistency. The teams involved in the project needed to be highly focused on throughput, given the substantial weight of the t-beams (80 lbs each). Efficiently stacking the beams for galvanizing was essential to meet the production requirements. A partnership between the galvanizer and customer was essential to the project’s success.

The project's focus on efficiently galvanizing the steel t-beams, which serve as a critical component of the new acoustical barrier system, demonstrates a commitment to creating a long-lasting, durable, and hurricane-resistant solution. This project not only addresses noise reduction but also has economic and employment benefits, making it a valuable asset to the Miami-Dade community for decades to come.