The Property Manager’s Guide to
Battery Garage Repair and Refurbishment
How to turn old battery/system garages into new, or just repair damage caused by accidents or storms
This booklet and website lists and illustrates nearly 30 different Battery Garage Systems including coverage of the major structural problems and how to deal with them. Also the improvement of existing stock to give old garages a new lease of life without the need to demolish and rebuild from scratch. This is portrayed in some depth.
Before and after detail is shown for many of the types indexed in this book and on this website together with critical aspects such as water inflow and spalling concrete. An index of types starts at page 22.
Copies of the 40 page fully illustrated A4 booklet are available free-of-charge, and they are better than a smart phone web view as real close-ups are invaluable when looking for examples of damage or decay.
We hope that this information will prove useful in your work.
Colin Hammond, the author of this publication can be reached on 07817 692 284 for further information if needed.
Page 1
Some Completed Projects – Single / Twin Units
Page 2
Some Completed Projects – Multiple Units
Page 3
More Before & After
Page 4
Now for a more challenging refurbishment
This block of System B Garages was partly demolished by a large tree falling in the middle of the first four garages from the left hand end. While we have several moulds for the lintels and posts, of this type, we have but small numbers of moulds for the three types of panels used in this design. Without a quantity of the these moulds it would have taken weeks/months to make enough concrete panels to complete the job. Therefore we used standard Marley-Designed panels for the sides, rear and interwalls of the reconstruction.
The above pictures show the problem.
However the marriage of the two systems worked well with the final result mantain the original look and matching the other units in the block.
Page 5
Another way to refurbish garages – but not our way!
Page 6
And now for the Specifics
All about the Concrete
There are certain concrete parts of Concrete Battery/System Garages that start to deteriorate badly after 15-20 years and if left for 35-50 years can and do pose a health risk with the advent of falling concrete. However it is almost always the front post and lintels that are the problem. The main shell of the garage is usually re-useable and retaining it can save thousands of pounds for even a small block.
There is another issue here. Liability in the event of falling concrete sections injuring people. Cases of this nature have occurred and the Insurance Companies deny such claims pointing out that the building was not properly maintained. Thus the owner is liable for the Court award sometimes in six figures in cases brought by the HSE . We are advised that even if a management company looks after the garage for the owner the claim would still be against the owner, however the owner may then have a claim against the management company.
In the main the concrete panels that have not been subject to collision and/or have not been subject to spalling can be left in place for another 30-50 years. This saves removal and disposal costs which are continually rising. Retaining the existing panels is a much more “green” approach and although we loose business by suggesting that the original concrete be retained we do not want to make work that is not necessary. A site survey soon shows which concrete needs to be replaced and which doesn’t. Inside the garage the purlins may have hairline cracks and they do need to be replaced for reasons of safety.
Here are some examples of concrete lintels and posts that are disintegrating:
Block Refurbishment
Page 7
More problems with the concrete. With some Marley models there is a problem with the upstand at the top of the post/downpipe. This extension “blade” at the top of the post breaks off and falls. I weighs about 20lbs. This could injure anyone standing below it.
With System B and several other now obsolete types there are other problems.
An additional problem here is the post width used by Marley (and others using the same concept) to accomodate their rainwater downpipe. This measures 235mm in width and frames the door. This concrete post not only reduces the Wing Mirror Clearance (WMC) but splits or spalls zing shown. This is a result of water freezing in the blocked downpipes.
Wih a roller shutter door the post/downpipe is the same thickness as the garage dividing wall only the roller shutter door guides protrude into the WMC thus increasing the WMC to 2294mm. Therefore the extra WMC obtained over the original Marley door is 2294-2179=115mm (nearly 5 inches) and over a Hormann door 2294-2024=270mm (over 10 inches).
With all types – Purlin failure.
Inside the garage there are more hazards, in particular cracking purlins that support the roof. They start as hairline cracks, often resembling cobwebs. It they don’t then they need to be replaced, and soon.
Page 8
With System B the problem is much the same.
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With our roller shutter door there is no mechanism. The spring and other parts are contained within the roll of slats. And, as an added benefit, there are no levers and springs exposed which could be a safety hazard. Plus all of the interior space is available for storage and shelving.
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Page 13
More about Safety, Liability and Security
So the ideal System or Battery Garage would have non-corroding lintels, non-corroding downpipe posts to carry the rainwater away, a component to stop under panel water ingression and inexpensive, current guttering to add a modern look at very low cost. Our new System LX meets all of these criteria.
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Page 15
Note the aluminium joining post in the centre of the rear wall. In this garage this post has increased the width by 76mm (3″) which means 3″ of extra wing mirror clearance when driving in. Also on the outside of the building the post has sockets to support solar panel arrays or lighting or security camers, even flower baskets! These posts can be inserted into the walls at any point giving a multitude of options.
Page 16
All about Maintenance Problems
The fascia gutter cover on the right (not ours) needs to be removed for gutter cleaning. This envolves removing and replacing 30-40 self tapping screws, which after a few removals will have opened up their hole so that they no longer hold and larger screws will be needed. With our gutters you just blow or brush them out. See the roof view on page 10.
Yes, this is the front of the garage. In our System 8FX we use accessible square flow uPVC guttering that is easily cleaned by anyone with a short ladder and no tools.
All about Collision Damage
Page 17
All abouts Costs
There are two kinds of expense related to battery/system garages – one off repairs and block refurbishment and the approach is different. See page 18.
All One-off repairs
This is required where there has been some kind of impact. A vehicle hits the garage or a tree falls on the roof for instance. Occasionally a garage within a block may have deteriorated to the extent that chunks of concrete are falling from a lintel that is breaking up. In this case it is better to look at the block as a whole for there will be other garages in the block in a similar state and total refurbishment of the block will prove to be much more cost effective. Apart from the Marley and Leofric Ranges of garages we have moulds for other brands long since defunct and can usually provide a viable solution. However these replacement parts contain hand-made wire re-enforcement elements and require careful handling to ensure no cracking in the hardening stage, and even with great care taken the yield is not high and the costs reflect that. Evidence of the difference in the re-enforcement between Marley and other brands can be seen in how they disintegrate. Marley units spall (concrete comes away from the rebar) System B from a manufacturer long since gone, breaking up along the lintel. Note in the photograph how the concrete has collapsed onto the door which is now the only thing holding it up!
Page 18
System LX Battery Garage Detail
The front post which doubles up as the down post with 2.8 times the capacity of the current pipes that are encased in concrete. Virtually no chance of a blockage.
The roller shutter door guides slide into the front post. This gives an integrated lintel support section equal to an “I” Beam measuring 200mm by 150mm and 5mm thick. Which is massive.
The “Z” shaped alumnium lintel which supports the roof sheets is fixed to the post/guides combo.
Page 19
Here are the images of what we have described
The aluminium downpipe/post will not block easily, unlike the interpost pipes of earlier models. In fact the new post/pipe has about three times the capacity of the original Marley design or the System “B” Type .Debris drops out of the pipe and is easily brushed away.
Leofric’s unique Base Plate Bitumen
Page 20
Or, if you wish to give your existing concrete shells an up-to-date look then this
or this
can become
this
with new, maintenance-free fronts, and roller shutter doors, but retaining all the existing concrete shell structure thereby extending the life of your garage block for another 40-50 years.
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System B
Very popular design. Often seen in the Midlands and the South. Manufacturer went out of business probably 50 years ago. All parts have been re-moulded by Leofric and are available. Can be converted to System X fronts and Roller Shutter Doors. For more information see Page 27.
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System C
Similar to Marley and Leofric Models in that they feature 16″ wide wall panels that are 7′ high. Not tongued and grooved like Marley. Manufacturer went out of business about 10 years ago. Can be converted to System X fronts and Roller Shutter Doors. Few examples around.
System E
Unknown manufacturer. Posts are embedded in the base. Walls are Post and panel construction. No parts available. Best demolished. No Further information.
System K-8F
This is a Post and Panel Garage System with concrete fascia/gutter/lintels and downpipes. No parts available but easily converts to System X fronts.
System L
Early Leofric Model – all parts available. Can be converted to System X fronts and Roller Shutter Doors. For more information see Page 28.
System M-8G
Early Leofric Model – all parts available. Can be converted to System X fronts and Roller Shutter Doors. For more information see Page 29.
System M8/9R
Very early Marley Garage – extra wide rear-sloping design using Marley A63 panels. Can be converted to System X fronts and Roller Shutter Doors.
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System M-H
This garage style used Marley’s Top-of-the-line Heritage Range in a
Battery format. All parts are available. For more information see Page 30.
System M-Q
Another early Marley design. Can be converted to System X fronts and Roller Shutter Doors. For more information see Page 31.
System M-E8/9 F/R
Marley Economy Range. Available with 8′ or 9′ interior widths. All parts available. Can be converted to System X fronts and Roller Shutter Doors. For more information see Page 30.
System M8/9F
Current Marley design. All parts available and can be converted to System X fronts and Roller Shutter Doors. For more information see Page 32.
System M8/9R
Current Marley design. All parts available and can be converted to System X fronts and Roller Shutter Doors.
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System FMTF
Unknown manufacturer. Probably best demolished. For more information see Page 32.
System TAR
Manufacturer long gone. If significant quantities of parts are required then moulds can be made. For more information see Page 35.
System TPP
Probably Cotswold. Long gone, no parts available. Walls are large Four foot square panels. No parts available. For more information see Page 36.
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System V
Probably Cotswold. Long gone, no parts available. Walls are large Four foot square panels. No parts available. For more information see Page 36.
System WMR
Obsolete design. No parts available. For more information see Page 37.
System WPF
Obsolete design. No parts available. For more information see Page 37.
System WNR
Obsolete design. No parts available. For more information see Page 38.
System YPP
Obsolete design. No parts available. For more information see Page 38.
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System B Battery Garage Detail
System B battery garage form the garage stock of many local authorities and as the original mnufacturer went out of business 30-40 years ago we have manufactured moulds for all 12 concrete components.
Common problems are lintels failing, posts disintergrating, and door mechanism mounting panels cracking.
System B battery garage form the garage stock of many local authorities and as the original mnufacturer went out of business 30-40 years ago we have manufactured moulds for all 12 concrete components.
Common problems are lintels failing, posts disintergrating, and door mechanism mounting panels cracking.
Page 27
System L Battery Garage Detail
System L battery garage (for Leofric) started life as a Banbury Garage. When Banbury split into Compton and Leofric, Compton dropped Battery Garages but Leofric continued with the product. That is why we can still supply parts, fifty or so years later. The main difference between System L and System E is that the System L is built from the rear corners forward whereas System E relies on posts sunk into the concrete base and then built backwards.
System L battery garage is simple. However the original lintel and front gutter design used a metal section, largely hand made. Today we would replace the fronts with System X components.
Before
After
However in some cases re-manufacturing the metal box is more desirable as it matches adjoining garages as shown below.
Page 28
System M-8G Battery Garage Detail
The System M-8G battery garage was an early Marley product and can be identified by a number of characteristics but the two instantly recognisable ones are the construction using 16″ panels combined with the unstoned, rounded-off edges of the panels.
These garages have lintel/fascias that in many cases have completely broken down (having been constructed over 50 years ago). In the photo below we can see that the entire fascia has become crumbled aggregate.
The shell of the garage is usually sound unless it has suffered from a collision and even this garage can be given a new lease of life by conversion to the System LX format.
Recently the lady using this System M-8G garage shut the door (perhaps too vigorously) whereupon the lintel on her garage, similar to the one on the right, crashed to the ground just missing her. Obviously this is dangerous to the person shutting the door or to children using the garage front for soccer practice or similar activity.
Page 29
System M-E8/9 F/R Battery Garage Detail
These System ME8/9 battery garages are current Marley-designed Leofric built Models and seldom need refurbishment for deterioration but often require repair following vehicle collisions and falling trees or base disruption due to adjacent tree growth. All parts are available, however System LX components will fit to these units to extend building life and enhance apprearance.
System M-H Battery Garage Detail
This System MH Battery Garage is based on the Marley (now Mayfair Garages) Heritage Model. It has an apex roof which sets it alone in the battery or system garage ranges. The model shown has a smooth panel finish whereas most have a dark, chipped stone surface as shown in the example needing repair! See page 34. All parts are available.
Page 30
System M-Q Battery Garage Detail
This System MQ battery garage is a very early Marley design known as The Marley Master. The System MQ battery garage panels are 16″ wide and 6′ high, they are tongued and grooved and sit on a 6″ plinth.This particular example has been completely re-faced so only the end and rear walls give any indication of the type.
Note the posts located between the first and last three panels which are themselves slightly flared out towards the base. This type of construction is unique. Also note the wedge shaped concrete mounted on the side panels to give the roof drainage pitch.
Page 31
System M8F/R Battery Garage Detail
These system M8F/R battery garages are still in our current range. Most are in good condition but they do suffer from collision damage from time to time. All parts are available.
This is how the M-8F looked after a repair. The Type indicates the slope of the roof, F slopes and drains to the front. The R slopes backwards and drains to the rear. The 8 or 9 indicates the internal width of the garage. All System M8F/R Garages can be converted into System X format.
System FMTF Battery Garage Detail
This System MTF Battery Garage type is based on an early Marley Panel Garage and could be refurbished with System LX components on the fronts, aluminium posts and downpipes with uPVC gutters and fitted with Roller Shutter Doors. This concrete garage is similar to the MQ but has more exaggerated flared side/end posts.
Page 32
System FMTR Battery Garage Detail
This System FMTR Battery Garage type is based on an early Marley Panel Garage and could be refurbished with System X components on the fronts with aluminium posts and fitted with Roller Shutter Doors. To the rear we would fit uPVC gutters and downpipes.This concrete garage has the flared side posts but not the tapered wedges that create the roof slope of the MQ.
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System P Battery Garage Detail
These garages can be identified by the “V” shaped moulding in the middle of the front fascia. Also this is one of the few Battery Garage Systems that is constructed with posts and panels similar to the System L. System L panels would probably fit although the appearance would differ slightly. No fascia moulds exist for this type. System X parts can be employed across the fronts. The brand is unknown at the present time but they have been observed from Dover to Plymouth.
Page 34
System TAR Battery Garage Detail
This System TAR Battery Garage panel garage has a few identifying features. Note the square insert of the fascia notched into the post/downpipe.
Also the height of the side panels at 94″, higher than Marley although still a 16″ panel against the 24″ panel of System “B”.
Note also the gap between panels which shows evidence of a tongue and grooved joint although not as pronounced as a Marley joint. Can be upgraded to System X.
Page 35
System TPP Battery Garage Detail
This is a rare post and panel type that would be hard to convert to a System X frontal format.
System V Battery Garage Detail
This System V battery garage is a post and panel arrangement with large panels especially in the rear wall. Posts, lintels, inner and rear panels usually show evidence of cracking and when the lintels crack they fall down onto the door frames rendering the garage unusable.
Page 36
System WMR Battery Garage Detail
This brick-built system WMR battery garage shell and solid concrete garage lintel design can be fitted with our new roller shutter doors and the concrete fascia cladded with soffit uPVC to give the garages a modern look extending their life for another 30-40 years.
System WPF Battery Garage Detail
This system WPF Battery Garage is an unusual design incorporating a roughcast rendered “buttress” shape between garages. Roller shutter doors can be fitted to modernise the look and provided much cheaper repair costs in the event that doors are damaged by collision.
Here the “shell” is constructed with post and panel concrete sections which can often be retained for an extended useful life.
Page 37
System WNR Battery Garage Detail
These rear-sloping roof garages are of post and panel construction with end and interposts sunk into the base. As the concrete lintels are often cracked we recommend replacing the lintels with powder-coated aluminium sections covered with uPVC soffit material and fitting the units with roller shutter doors.
System YPP Battery Garage Detail
This is a Post and Panel System YPP battery garage that is not common and we have only seen it in one location. Although similar to System L the joints of the two systems are not compatible, neither can the new aluminium posts that can replace System L corner and interposts be used with this System. These garages have had their life and need to be replaced.
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