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Ph 0800 655 200 or visit www.csppacific.co.nz
Oclyte™ Modular Octagonal Steel ColumnsProduct & Installation Manual
CS
P P
acifi
c | O
clyt
e™ P
rod
uct
& In
stal
latio
n M
anua
l | M
ay 2
011
CS
P P
acifi
c | O
clyt
e™ P
rod
uct
& In
stal
latio
n M
anua
l | M
ay 2
011
02
OclytetM
LightingColumns
Introduction 04
Streetlight columns 06Standard ground planted 08Standard shear or flange 09Pedestrian crossing 10Subdivision column 11Standard outreaches 12Alternative outreaches 13
Floodlighting columns 14Floodlight Columns and Cross Arms 15Seesaw - lowering column 16Planting options 17Holding-down assemblies 18Oclyte™ column identification 19
Assembly and installation instructions
20
Shear base assembly, installation and maintenance
26
Optional corrosion protection Oclyte™ Tuff Coat™
28
Contents
03
Introduction
The Oclyte™ modular steel column is now a familiar sight in most towns and cities of New Zealand and has gained wide acceptance in Australia, the Pacific Islands and South East Asia.
The column comprises a range of interchangeable octagonal tapered steel elements each of which friction-fit together to provide the desired height.
Benefits
Competitively priced
Automation of production has provided a very efficient and
low cost manufacturing process. This is reflected in the
purchase price and combined with a low installation cost
provides the client with a very competitively priced pole.
Safe design
The lightweight steel construction minimises both personal
injury and property damage when struck by vehicles. A
special frangible base which shears off on impact, is used
in areas with a high traffic density to further reduce the
possibility of serious injury.
Aesthetics
The continuous tapering octagonal shape from spigot to
base provides a visually pleasing and unobtrusive form in
street furniture.
Low maintenance and repair costs
The modular construction permits replacement costs to be
restricted to only the affected elements, eliminating the need
for total pole renewal.
Hot dip galvanizing after fabrication to AS/NZS 4680:1999
- Hot Dip Galvanized (Zinc) Coatings on Fabricated
Ferrous Articles, ensures long service life without costly
maintenance.
Typical coating weights are 500–550 g/m2.
Ease of transportation, storage and assembly
With the modular elements nesting inside one another
transportation and storage costs are reduced.
Further savings are gained during assembly where the
lightweight elements can be readily mated to friction fit
without craneage or sophisticated erection equipment.
Versatile design
The wide range of interchangeable elements provides top
flexibility in column selection as is evidenced in the following
tables.
This combined with the potential to vary the steel thickness,
as dictated by the imposed loads, gives an economic design
without compromising the aesthetics.
04
OclytetM
LightingColumnsColumn Applications
Applications
Street Lighting
Undergrounding of electricity has led to an increasing demand
for an aesthetically pleasing column for street lighting in both
residential and commercial areas.
The Oclyte™ series provides an extremely versatile combination
of mounting heights, base types and outreach shapes to satisfy
the requirements of the most fastidious designer.
The standard columns are detailed in the following illustrations.
Floodlighting
Security requirements, outdoor displays, sportsfields and work
areas require varying degrees of llumination which in turn need a
versatile column on which to fix the appropriate lanterns.
A wide range of Oclyte™ columns of varying design capacities
are available to maximise the illumination needed and these are
detailed later.
Communication Columns
A number of communication systems, utilising radio and/or
microwaves, require columns of minimum deflection and heights
in excess of 20 metres.
Oclyte™ columns are widely used for this purpose and are
usually individually designed.
Power Transmission
Remote or difficult areas may require a modular column for ease
of installation. Oclyte™ has been successfully used for both low
and high tension lines.
05
Streetlight columns
06
OclytetM
LightingColumns
Standard DimensionsThe standard module is 3.6 metres in overall length with the net
length varying with the lap.
Gear Opening SizesStandard sizes for gear openings are:
Elements 0–1/2 150 × 75
Elements 2–7 300 × 150
Spigot SizesSpigot sizes are generally 34 or 42mm OD × 150mm long for
street light fittings and 76mm OD × 110mm for post top fittings.
It is necessary to specify size and length when ordering.
FoundationsColumns are either ground planted or flange mounted.
Ground Planted
Columns are planted to depths shown in the tables (as a guide
only) assuming “good ground” as per NZS 3504:1999.
It is recommended that a hole approximately 200mm diameter
oversize is excavated to allow for placement of selected granular
(GAP20 or similar) or dry concrete backfill (min. 20Mpa) around
the column.
Flange mounted
Concrete footings are designed by others to suit column
loadings as supplied by CSP Pacific.
Standard holding down bolt assemblies are available. Care
should be taken to ensure correct orientation of H.D. bolts
during footing construction and a template must be used to
ensure correct spacing of bolts for the circular type assemblies.
Column AssemblySee the detailed Installation Instructions on pages 20 to 27 of
this manual.
ManufactureThe columns are manufactured from mild steel with a minimum
yield of 250 MPa ranging in thickness from 2–10mm which, after
folding, are seam welded and then hot dip galvanized to AS/NZS
4680:1999.
Higher yield steels are also used where high loads and taper
constraints dictate.
DesignThe Oclyte™ columns are computer designed, based on
the sail area for the particular wind speed at installation. The
sophisticated programme ensures an exact evaluation of the
pole loadings and thus an efficient design to Australian and
New Zealand Design Codes NZS 3404: 1997, AS/NZS 4600:
1996, AS/NZS 1170: 2002 and AS/NZS 4676:2000.
The elements are generally 3.6 metres in length with half
sections used where necessary to provide a full range of
mounting heights. They are enumerated from section ‘O’ at the
top on an approximate taper of 21mm per metre.
Element Number
Across Flats at Base of
Element (mm)
Approx Mass (kg) After Galvanizing Steel
2 mm Steel
3 mm Steel
0 89 12.5 -
1 155 23.6 35.2
2 220 36.5 54.5
3 282 49.0 73.0
4 342 61.0 90.8
5 400 72.8 108.2
6 457 83.9 124.7
7 511 - 140.9
Streetlight columns
07
Standard ground plantedO
MIN
AL
MO
UN
TIN
G
HE
IGH
T(m
)
DW
G N
O.
ELE
ME
NTS
U
TILI
SE
D
CO
LUM
N H
EIG
HT
WIT
HO
UT
O/R
(m)
PLA
NTI
NG
D
EP
TH(m
)
WE
IGH
T C
OLU
MN
O
NLY
(kg)
ACTUAL TOTAL HEIGHT OF COLUMN WITH OUTREACHES (MEASURED TO SPIGOT FROM G/L)
CURVED (Dwg No. P602) MITRED (Dwg No. P603)ELLIPTICAL (Dwg P470 &
P1903)
1.0m 2.0m 3.0m 4.0m 1.0m 2.0m 3.0m 4.0m 2.5m 4.0m
ST
RE
ET
LIG
HT
CO
LU
MN
S -
GR
OU
ND
PLA
NT
ED
5.5 P1590 1-1/2 2 3.96 1.2 40.0 5.52 5.75 5.95 6.15 5.46 5.32 5.67 5.85 - -
7.0 P724 1-2 5.42 1.5 60.0 6.97 7.20 7.40 7.60 6.91 6.77 7.12 7.31 - -
7.5 P912 1-2 3.62 1.5 50.0 - - - - - - - - 7.67 8.41
8.0 P725 1- 1/2 3 6.52 1.8 83.0 8.08 8.31 8.51 8.71 8.02 7.88 8.23 8.41 - -
9.0 P911 1- 1/2 3 4.72 1.8 74.0 - - - - - - - - 8.78 9.52
10.0 P713 1-3 8.12 2.0 110.0 9.68 9.91 10.11 10.31 9.62 9.48 9.83 10.01 - -
10.5 P714 1-3 6.32 2.0 100.0 - - - - - - - - 10.38 11.12
11.0 P717 1- 1/2 4 9.21 2.2 138.0 10.77 11.00 11.20 11.40 10.71 10.57 10.92 11.10 - -
11.5 P718 1- 1/2 4 7.41 2.2 128.0 - - - - - - - - 11.47 12.21
11.75 P1782 1- 1/2 4 9.72 1.7 138.0 11.28 11.51 11.71 11.91 11.22 11.08 11.43 11.61 - -
12.0 P1345 1-4 10.23 2.4 160.0 11.79 12.02 12.22 12.42 11.73 11.59 11.94 12.12 - -
12.5 P905 1-4 10.71 2.5 170.0 12.27 12.50 12.70 12.90 12.21 12.07 12.42 12.60 - -
13.0 P906 1-4 8.91 2.5 160.0 - - - - - - - - 12.97 13.71
13.5 P931 1- 1/2 5 11.62 2.8 205.0 13.17 13.40 13.60 13.80 13.11 12.97 13.32 13.51 - -
14.0 P932 1- 1/2 5 9.82 2.8 195.0 - - - - - - - - 13.87 14.61
0
OUTREACH
SPIGOT SIZED TOSUIT LANTERN
GEAR OPENING
150 × 75 CABLE ENTRY
‘G’
‘C’
MO
UN
TIN
G H
EIG
HT
GR
OU
ND
PL
AN
TIN
G
DE
PT
H
10º
3
1
2
0
3
1
2
OUTREACH
25º
0
1
2
3
OUTREACH
SPIGOT17º
CURvED ELLIPTICAL MITRED
08
OclytetM
LightingColumnsStandard shear or flange
OM
INA
L M
OU
NTI
NG
H
EIG
HT(
m)
DW
G N
O.
ELE
ME
NTS
U
TILI
SE
D
CO
LUM
N H
EIG
HT
WIT
HO
UT
O/R
(m)
PLA
NTI
NG
D
EP
TH(m
)
WE
IGH
T C
OLU
MN
O
NLY
(kg)
ACTUAL TOTAL HEIGHT OF COLUMN WITH OUTREACHES (MEASURED TO SPIGOT FROM G/L)
CURVED (Dwg No. P602) MITRED (Dwg No. P603)ELLIPTICAL (Dwg P470 &
P1903)
1.0m 2.0m 3.0m 4.0m 1.0m 2.0m 3.0m 4.0m 2.5m 4.0m
ST
RE
ET
LIG
HT
CO
LU
MN
S -
SH
EA
R/F
LA
NG
E B
AS
ED
5.2 P2130 1 3.72 1.2 (FB), 1.8(SB) 40.8 5.27 5.50 5.70 5.90 5.21 5.07 5.42 5.61 - -
7.0 P924 1- 1/2 2 5.23 1.5 (FB), 1.8(SB) 58.0 6.79 7.02 7.22 7.42 6.73 6.59 6.94 7.12 - -
8.5 P923 1-2 7.03 1.5 (FB), 1.8(SB) 76.0 8.59 8.82 9.02 9.22 8.53 8.39 8.74 8.92 - -
9.3 P922 1-2 5.21 1.5 (FB), 1.8(SB) 68.0 - - - - - - - - 9.27 10.01
9.5 P723 1- 1/3 3 7.82 1.8 95.0 9.37 9.60 9.80 10.00 9.31 9.17 9.52 9.71 - -
10.0 P894 1- 1/2 3 8.44 1.8 103.0 9.99 10.22 10.42 10.62 9.93 9.79 10.14 10.33 - -
10.0 P903 1- 1/3 3 6.02 1.8 85.0 - - - - - - - - 10.07 10.81
10.5 P716 1- 2/3 3 9.04 1.8 to 2.4 118.0 10.59 10.82 11.02 11.22 10.53 10.39 10.74 10.93 - -
10.7 P919 1- 1/2 3 6.62 1.8 93.0 - - - - - - - - 10.67 11.41
11.3 P901 1- 2/3 3 7.22 1.8 to 2.4 108.0 - - - - - - - - 11.27 12.01
12.0 P720 1-3 10.24 1.8 to 2.4 140.0 11.79 12.02 12.22 12.42 11.73 11.59 11.94 12.13 - -
12.5 P896 1- 1/3 4 10.93 2.4 154.0 12.48 12.71 12.91 13.11 12.42 12.28 12.63 12.82 - -
12.5 P893 1-3 8.42 2.4 129.0 - - - - - - - - 12.47 13.21
13.0 P917 1- 1/2 4 11.53 2.4 164.0 13.08 13.31 13.51 13.71 13.02 12.88 13.23 13.42 - -
13.2 P721 1- 1/3 4 9.11 2.4 143.0 - - - - - - - - 13.16 13.90
13.8 P918 1- 1/2 4 9.71 2.4 153.0 - - - - - - - - 13.76 14.50
15.0 P1795 1-4 13.33 3.0 197.0 14.88 15.11 15.31 15.51 14.82 14.68 15.03 15.22 - -
15.5 P1796 1-4 11.51 3.0 186.0 - - - - - - - - 15.56 16.30
Note: Any of the three outreach types may be combined with either type of base. Standard holding down bolt assemblies or ground
stubs available for flange mounted columns.
0
OUTREACH
SPIGOT SIZED TOSUIT LANTERN
GEAR OPENING
150 × 75 CABLE ENTRY
‘G’ 75
700
MO
UN
TIN
G H
EIG
HT
GR
OU
ND
PL
AN
TIN
G
DE
PT
H
10º
3
1
2
0
1
2
OUTREACH
25º
0
1
2
OUTREACH
CONCRETE FOOTINGBY OTHERS
SPIGOT17º
‘G’
CURvED ELLIPTICAL MITRED
09
Pedestrian crossing
BenefitsThe CSP Pacific Oclyte™ pedestrian crossing pole offers the following benefits:
Aesthetics — Continuously tapered octagonal shape
provides a visually pleasing form.
versatility — Due to modular construction, gear opening
position, direction of spigot for Belisha beacon and outreach
direction can be varied to suit the installation as required.
Modular — The pole consists of three sections which simply
friction-fit together. Assembly, transportation and storage
costs are thus minimised, and only damaged sections need
to be replaced
Safe design — Light weight galvanized steel construction
minimises both personal injury and property damage if
struck by a vehicle.
1
GEAR OPENING
CABLE ENTRY
450
GR
OU
ND
PL
AN
TE
D
1.0m
MO
UN
TIN
G H
EIG
HT
5.8m
3.0m
300
GROUND LEVEL
1¼” B.S.P.SOCKET FOR
BEACON
OUTREACH
0.9m CURVED 42mm O.D. SPIGOT
10º
2
0 Ø 2
6
1” B
SP
TAP
ER
ED
TH
RE
AD
25Ø
34
2
2º
SPIGOT PLAN
SPIGOT ELEVATIONSCALE – NTS
21
46
SPIGOT DETAILSCALE – NTS
25mm (1”)BSP SPIGOT
30
10
OclytetM
LightingColumnsSubdivision column
BenefitsCSP Pacific has designed the Oclyte™ Subdivision column as an answer to the increasing costs of land sub-division and to meet modern road safety and aesthetic requirements.
Lightweight
Because the Oclyte™ subdivision column is less than 50 kg in
weight, installation costs can be greatly reduced. Columns can
be lifted and erected by two men without special lifting gear.
Modular
The pole consists of sections which simply friction-fit together.
Assembly, transportation and storage costs are thus minimised.
Aesthetics
Continuously tapered, octagonal shaped from spigot to base
provides a visually pleasing form.
Competitively Priced
Automation of production on a standard unit and large
production runs, combined with low installation cost, provides
the client with a competitively priced column.
Safe Design
Light weight galvanized steel construction minimises both
personal injury and property damage if struck by vehicles.
Uses
Residential sub-divisions, retirement villages, hospitals, military
camps.
OUTREACH
34mm O.D. SPIGOT
3.6m
3.6m
GEAR OPENING
GROUND LEVEL
CABLE ENTRY
0.6m
0.6m
MO
UN
TIN
G H
EIG
HT
GR
OU
ND
PL
AN
TE
D
10º
0
1
Mounting Height
Outreach
(m)DWG No.
Elements Utilised
Planting Depth
Weight Column Only
(kg)
6.0 0.9 P461 0-1 1.0 38.0
6.0 1.5 P1774 0-1 1.0 38.0
7.3 0.9 P547 0-½2 1.3 53.0
7.3 1.5 P1679 0-½ 2 1.3 54.0
11
Standard outreaches
10º
10º
1050 4000
SPIGOT DETAIL
1720
00
00
0 0
1800
1950
2900
600 LONG SPIGOT
2050
2200 150
10º
10º
1050 4000
SPIGOT DETAIL
1720
00
00
0 0
1800
1950
2900
600 LONG SPIGOT
2050
2200 150
10º
10º
1050 4000
SPIGOT DETAIL
1720
00
00
0 0
1800
1950
2900
600 LONG SPIGOT
2050
2200 150
10º
10º
1050 4000
SPIGOT DETAIL
1720
00
00
0 0
1800
1950
2900
600 LONG SPIGOT
2050
2200 150
20003050
600LONG SPIGOT
SPIGOT DETAIL
17º0
0
00
0
0
1520
1870
4000
2058
1000
1660
150
53.5º
MITRE DETAIL
MITRE WASHER
SEE SPEC.
20003050
600LONG SPIGOT
SPIGOT DETAIL
17º0
0
00
0
0
1520
1870
4000
2058
1000
1660
150
53.5º
MITRE DETAIL
MITRE WASHER
SEE SPEC.
20003050
600LONG SPIGOT
SPIGOT DETAIL
17º0
0
00
0
0
1520
1870
4000
2058
1000
1660
150
53.5º
MITRE DETAIL
MITRE WASHER
SEE SPEC.
20003050
600LONG SPIGOT
SPIGOT DETAIL
17º0
0
00
0
0
1520
1870
4000
2058
1000
1660
150
53.5º
MITRE DETAIL
MITRE WASHER
SEE SPEC.
CURvED ELLIPTICAL
MITRED
1518
4330
282
1
0
SEE DETAIL A
DETAIL A
BUTT WELD
SECTION 1
COUPLING LINER SECTION 0
50
5
247025º
STANDARD 34Ø OR 42Ø SPIGOT
(STANDARD TILT - OTHER TILTS ARE ALSO AVAILABLE)
1518
4330
282
1
0
SEE DETAIL A
DETAIL A
BUTT WELD
SECTION 1
COUPLING LINER SECTION 0
50
5
247025º
STANDARD 34Ø OR 42Ø SPIGOT
(STANDARD TILT - OTHER TILTS ARE ALSO AVAILABLE) 15
1843
30
282
1
0
SEE DETAIL A
DETAIL A
BUTT WELD
SECTION 1
COUPLING LINER SECTION 0
50
5
247025º
STANDARD 34Ø OR 42Ø SPIGOT
(STANDARD TILT - OTHER TILTS ARE ALSO AVAILABLE)
12
OclytetM
LightingColumnsAlternative outreaches
DOUBLE OUTREACH STAND-OFF BRACkET (Post or Wall Mounting)
TRIPLE OUTREACH
13
Floodlighting Columns
14
OclytetM
LightingColumns
Floodlight Columns and Cross Arms
Note: Standard holding down bolt assemblies available
or special ground stubs.
SMILEY FACE CROSSARM OPTION
ELEVATION
PLAN
FLOODLIGHT COLUMNS - GROUND PLANTED
Noiminal Mounting
Height (m)
Column Gauge DWG NO. Elements
Utilised
Planting Depth /
HDA(m)
Column Weight Only(kg)
4.2 2mm P1552 1-1/2 2 0.9 41.0
5.7 2mm P1335 1-2 1.2 63.0
5.7 2&3mm P1804 1-2 1.2 81.0
5.7 3mm P2253 1-2 1.2 92.0
7.0 2mm P1553 1-2/3 3 1.9 86.0
7.0 2&3mm P1805 1-2/3 3 1.9 115.0
8.5 2mm P1347 1-3 1.7 112.0
8.5 2&3mm P1806 1-3 1.7 136.0
9.7 2mm P1334 1-1/2 4 1.9 141.0
9.70 2&3mm P1807 1-1/2 4 1.9 179.0
9.7 3mm P1808 1-1/2 4 1.9 208.0
11.2 2mm P1765 1-4 2.2 173.0
11.2 2&3mm P1333 1-4 2.2 227.0
11.2 3mm P1809 1-4 2.2 256.0
12.2 2mm P1514 1-1/2 5 2.5 208.0
12.2 2&3mm P1764 1-1/2 5 2.5 278.0
12.2 3mm P1766 1-1/2 5 2.5 307.0
13.7 2mm P1554 1-5 2.8 247.0
13.7 2&3mm P1767 1-5 2.8 311.0
13.7 3mm P1768 1-5 2.8 364.0
14.7 2mm P1769 1-1/2 6 3.0 286.0
14.7 2&3mm P1770 1-1/2 6 3.0 371.0
14.7 3mm P1771 1-1/2 6 3.0 424.0
16.2 2&3mm P1555 1-6 3.2 436.0
16.2 3mm P1773 1-6 3.2 489.0
15
Seesaw – lowering column
DescriptionColumns are available in mounting heights generally as shown
on page 13. Both ground planted and flange mounted are
available.
The counter-balanced mast is lowered by simply loosening the
securing bolt and attaching a length of rope to the eyelet to
control the lowering of the column.
The only tools required are a spanner, length of rope and
occasionally a short ladder. No bucket trucks, cranes, climbing
rungs, hydraulics or springs, winches or other hoisting gear.
6
NO
MIN
AL
MO
UN
TIN
G H
EIG
HT
TO
SU
IT
1
3
4
5
2
16
OclytetM
LightingColumnsPlanting options
17
Holding-down assemblies
OUTSIDE Ø
POLE SECTION
PCD
INSIDE Ø
8x BOLT HOLE Ø FOR HOLDING DOWN ASSEMBLY BOLTS 25mm PLATE
GEAR OPENING
1
2
3
4
5
6
NON-SHRINK GROUT
GROUND LEVEL1050
18.1
m N
OM
INA
L M
OU
NT
ING
HE
IGH
T
Typical Square Type
Typical Circular Type
‘D’ mm PLATE
SLOTTED HOLESFOR HOLDINGDOWN BOLTS
‘B’ CRS
‘C’ I
.D.
‘A’
18
OclytetM
LightingColumns
Oclyte™ column identification
CROSSARM TYPE
F.L.C
m
ESTIMATEDSECTION LENGTH
No. OF SECTIONSEXCLUDING OUTREACH
mm
STEEL THICKNESSAT GEAR OPENING
(BOTTOM SECTION)
FIRST LAP FROM G.L.DETAIL ‘A’
m
m
DIS
TAN
CE
TO
FIR
ST
LA
P F
RO
M G
.L.
DETAIL ‘B’
GROUNDPLANTED
GROUNDSTUB
mm
HOLD DOWNASSEMBLY
J = FLANGE WIDTHOR DIAMETER
‘G’ ‘F’
‘H’
mm
‘K’
G.L.
KGEAR OPENING
HEIGHT
mm
mm
mm mm
GEAR OPENINGWIDTH
H = FLANGETHICKNESS
G = BOLT CENTREMEASUREMENT
F = BOLT CENTREMEASUREMENT
DETAIL ‘B’
mmS=
m
AT GROUND LEVEL(OR AT BASE FLANGE LEVEL)
MOUNTINGHEIGHT
=CSP TO COMPLETE
S.L.CS=
SAT FIRST LAP OFLOWER SECTION
mm
mm
DETAIL ‘A’
OUTREACH TYPE& SIZE
STEEL THICKNESS OFTHE SECOND SECTION
AT THE FIRST LAP
S
19
Standard ground plantedAssembly and installation instructions
20
OclytetM
LightingColumns
Assembly and installation instructions
1) General Oclyte™ poles are made up of tapered eight sided (octagonal) sections. The standard lengths of these sections are 3.6m and 1.8m, other lengths are possible depending on the nominal mounting height of the column. The column height is achieved by joining these sections together, the smaller end of one section slipping into the larger end of the one above. This then creates a friction joint between the town sections, the length of this joint is designed to be between 1.5x and 1.6x the AF (across the flats) dimension of the female section. See fig. 1 below.
This friction joint is sufficient as a stand alone joint, nothing else
is needed for strengthening. A silicon sealer can be used to
prevent capillary action of water up through the joint. (Contact
CSP Pacific for further information). The #1 section is always at
the top of column, onto which the outreach (Street light column)
or cross-arm (flood light column) is attached.
2) Receipt of consignmentPlease check the consignment carefully to ensure that the
components are correct for quantity, type and condition before
signing off the consignment note or waybill.
3) Assembly methodsThere are three main methods that can be used to asseble
Oclyte™ columns, the type of column to be assembled will
determine which method is used. The three methods are:
• Sledge Hammer method (refer to 5.1) – column height up
to 12m & steel thickness of 2mm
• The Strop method (refer to 5.2) – mainly for attaching
streetlight outreaches, or for column height up to 12m &
steel thickness of 2mm
• The Winch method (refer to 5.3) – column height above
12m or steel thickness 3mm or thicker
Always commence the assembly with the base section. The
assembly procedure requires the column to be assembled one
section at a time (fully tighten each lap joint before progressing
to the next section). Monitor the column at all times during
assembly, to ensure it remains straight in both horizontal
and vertical planes. Before assembly begins ensure that the
following preparations are done:
4) Assembly equipment a) General (all columns):
• Wirecutterstocutpackstraps
• Timberbearers
• Sledgehammerandtimberpacking
• Tapemeasureandmarkerpen
b) Streetlight columns incorporating an outreach arm
• Allgeneralequipmentasabove
• Streetwirerope(1) (the approximate length required
equals the mounting height of the column plus the
outreach length plus 1m)
• 2tonneTirforwinch(1)
• Softstrop(2)
Note(1): Items 2 and 3 are optional. Needed for Winch
method only.
Note(2): Item 4 is optional. Needed fro Strop method only.
c) High Masts columns 12m mounting height or
higher and/or 3mm steel gauge or thicker.
• Allgeneralequipmentasabove
• SteelwireRope(approximatelengthrequiredequals
the length of the column plus 3m)
• Oneortwo5tonneTirforwinchesorriggerhoist.
(two generally needed for columns 30m in height or
higher and/or 6mm steel gauge or thicker)
• Tirforframe
5) SITE PREPARATIONAssembly should be undertaken on a level platform and with the
pole base as close as is practical to the prepared foundation.
Initial preparations
• Ensure all lap surfaces are free from obstructions e.g. dirt,
stones, dents, galvanizing/weld lumps etc.
• Mark out the distance (1.5 x AF) on the male section prior
to assembly as a guide to the actual overlap achieved.
Also make an additional mark +100mm on small columns
and +200mm on large columns, which is to be used as a
reference mark, in case the design lap mark is exceeded.
The lap length should be between 1.5 and 1.6 times the
“AF” or “across the flats” dimension of the inside of the
female section at the bottom. The minimum acceptable lap
is 1.4 x AF. Please contact CSP Pacific if you are unable to
achieve the minimum lap (ph: 0800 655 200).
• Support the sections on bearers and ensure that they are
aligned for ease of mating.
• Ensure that each pole sections seam weld is aligned with
the adjoining one. (Note that this does not necessarily
apply for the joint of the top section to the outreach). When
climbing rungs are supplied, make sure that these are
aligned as well (right hand side rung on the upper section
succeeds left hand side on the lower one or visa versa).
MALE SECTIONFIGURE 1.FEMALE SECTION
1.5 × AF
AF
21
5.1) Sledge hammer method
The following procedure applies to the OclyteTM columns of
approximately 12m or less in mounting height manufactured
in 2mm steel gauge. For floodlight columns incorporating a
cross arm, steps 6 and 7 are to be ignored.
I) Ensure initial preparations are complete as per above.
II) Place the bottom end of the bottom section against
a firm support. Use timber packers in between if
there is no flange (e.g. ground planted column). Start
hammering the top of the second section via a timber
packer. Timber packers are needed to avoid damaging
(buckling) the slender walls of the column.
III) During assembly, the joint must be agitated to facilitate
mating. This can be achieved by tapping around the
joint area using a sledge hammer (or similar) and timber
packer.
IV) Ensure that the required lap is achieved.
V) Continue with the consecutive sections in the same
manner, until the column is fully assembled.
VI) Place the outreach against a firm supports as shown in
Figure 2. Advance it to the top section and engage the
two ends together as far as is possible ensuring that the
column and the outreach are aligned straight. Support
the column on timber bearers.
VII) Hammer the bottom of the column using a timber
packer. Push the outreach firmly against the supports
(fig. 2) and hold it like that. This is to prevent any
movement of the outreach during hammering of the
sections on it.
VIII) The cross arm (if applicable) must be attached last
5.2) STROP METHOD
The strop method is generally only used for attaching the
outreach to a fully assembled streetlight column, although
the technique can be used to assemble pole sections as
well.
Assemble all the sections except the outreach together
using either the Sledge hammer or the Strop Method.
Attach the outreach as follows:
I) Support the base of the bottom section against a firm
support. Advance the outreach to the top of the top section
and engage the two ends together as far as possible. Use
timber packers at the bottom if there is no flange base (e.g.
ground planted column).
II) Wind the strop several times around the straight portion of
the outreach near the lap. Pull the strop towards the bottom
of the column until the required overlap distance is achieved.
During pulling, the joint must be agitated as described
before
For pulling the strop down, depending on the equipment
available, there are two options:
• A hiab truck can be used and the strop can be pulled by the
lifting arm (fig. 3); or
• A tirfor winch can be used for pulling the strop.
Note:
Apply the force as centrically as possible when pulling the
outreach on to the column
5.3) WINCH METHOD (FOR ANY STEEL GAUGE)
The following procedure applies to OclyteTM columns of
medium and large size, i.e. approximately 12m mounting
height or higher and/or 3mm steel gauge or thicker. Street
lighting columns are not covered by the procedure below.
I) Assemble the tirfor and the frame at the base of the
bottom section. Feed the cable through the centre
looping it at the top end of the adjoining section around
a rigid bar bearing on the section (Figure 4). Ensure that
the bearing of the bar will not damage (buckle locally)
the top of the section during winching (e.g. use timber
packers). Also use timber packers at the bottom if there
is no flange base (e.g. ground planted column).
II) During winching, if needed, the joint can be agitated
to facilitate mating. This can be achieved by tapping
around the joint area using a wooden hammer (or
similar).
III) Continue winching until the lap is fully tight, and
will close no further. Ensure that the required lap is
achieved. (Stop further winching if it causes column
to bow significantly, which can occur with slender
columns).
FIGURE 2.
USE TWO SUPPORTS FOR THE OUTREACHe.g. A WALL, TRUCK TYRES, A TREE,A KERB OR SIMILAR ITEMS.
SIDE SUPPORT IF NEEDED(STAKE DRIVEN INTOGROUND OR SIMILAR)
TIMBER PACKER
TOP OF PRE-ASSEMBLED
COLUMN
LAP MARK
PUSH THE OUTREACHFIRMLY AGAINST THE SUPPORTS
FIGURE 3.
Assembly and installation instructions
22
OclytetM
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IV) Continue with the consecutive sections in the same
manner, until the column is fully assembled.
V) The cross arm is attached last.
Note:
Monitor the column at all time during the winching procedure, to
ensure it remains straight in both horizontal and vertical planes.
6) Climbing rung assembly (if applicable)
I) Screw M24 and plain washer onto the onto the climbing
rung as far as possible.
II) Slide the other nut up the inside of the climbing rung
bracket on the pole section and hold in position.
III) Screw the climbing rung all the way into the second nut
in the climbing rung bracket.
IV) Tighten outer nut against the climbing rung bracket until
it lock the locks the rung.
Notes:
• Always ensure that the climbing rung up-stand is vertical
before tightening the nut.
• Refer to Figure 5 for the climbing rung assembly
7) Erection / lifting of assembled Oclyte™ columns
Two types of poles are available, ground planted and flange
mounted. The latter has a flange welded to the bottom section
and is either bolted to a hold down assembly (HDA) that has
been cast into a concrete foundation or bolted onto the flange of
a ground stub. The basic recommended erection procedure for
both these are primarily the same
7.1) Lifting equipment
• Crane,Hiaborsimilarliftingmachineisusedtoerectthe
column. The lifting machine should be adequate for the
pole weight and length. (A 30m pole will ordinarily require
a 18m jib and a rated lifting capacity of 12-15 tons).
• Webstropand/orsteelwireropeorsimilar.
• 2xHeavydutyspannerssuitablefortheholdingdown
nuts (for flange mounted columns).
• Spiritlevel
• Torquewrench
• Lubricatingoilforboltthreads
7.2) Preparation prior to erection
Prior to erection the column must be completely assembled.
Use the template (if supplied) to check holding down bolts
are in the correct position. Check whether all bolt and nut
threads are clear and undamaged and apply small amount
of lubricating oil to bolt threads. Level the lower set of nuts
on the holding down bolts.
The recommended point of lifting is approximately 2/3 up
the height of the pole. This is well above the centre of gravity
which is approximately 2/5 of the pole height from the base.
It should be noted that lifting point for some large columns
with big head frames can be different from the above and
special erection instructions are generally issued in such
cases
Attachment of the lifting hook to the pole can be achieved
using a web strop or similar, wound twice around the
octagonal section in such a manner that it will not slip
upwards when lifting commences. Locating this strop just
below the lap joint of a section, below a climbing rung or
other attachment is advisable.
Prevent sudden jerking movements during erection as this
may cause sections to loosen. This will not easily occur. As
a safety precaution a cable or strop should be attached at
the lifting point, then wrapped tightly around the column a
few times and attached near the base. The attachment point
used at the base depends on the size of the column. For
smaller and medium columns, the cable can be hooked into
the gear opening. For larger columns the cable should be
hooked to a stronger attachment point (e.g. an earth lug at
the base). (fig. 6)
Note:
If there is no access to the lifting point after erection, make sure
that the web strop is long enough to slip down the pole after
being loosened after the column is installed.
FIGURE 4.
LOOP OF WIRE ROPESECURED TO STEEL BAR
SECONDSECTION
BOTTOMSECTIONSTEEL WIRE
ROPE
‘TIRFOR’ WINCHOR RIGGER HOIST
PULLINGFRAME BEARERS
FIGURE 5.
PLAN ELEVATIONSIDE ELEVATION
MIN. POLE SECTION 3mm GAUGE
24mm DIAMETER GALVANIZEDBAR c/w M24×70mm THREADEDEND PART No. :2110049
MIN. POLE SECTION 3mm GAUGE
2× GALVANIZED NUTSAND ONE PLAIN WASHER
MIN. RADIUS
CLIMBING RUNG BRACKET
POLESECTION
POLESECTION
6
221
150
530
55
80
38
90
FIGURE 6.
THIS OPTION IS TO BE USED FOR LONG COLUMN LENGTHS
THIS OPTION IS TO BE USED FOR SHORT COLUMN LENGTHS
Assembly and installation instructions
23
8) Erection procedure – flange base columns
I. Mark the baseplate hole and the matching holding down
bolt prior to lifting.
II. Lubricate the threads of the holding down bolts with a
‘Holts lube stick’ (or similar lubricant) to ensure nuts are
free running.
III. Position the crane 6-8m from the centre of foundation
to centre of the jib turntable. Plan the operation so that
the column is lifted at approximately the same jib radius
needed for placing it over the foundation. (See fig. 7).
IV. Check column balance position and commence lifting
slowly - slewing jib continuously or frequently, in order to
keep hoisting rope vertically.
V. When column is standing almost upright, firstly hoist
it clear of the ground, then lower it very slowly into
position over the foundation.
VI. By manual means make last positional adjustments so
that holding down bolts are aligned with the correct
holes.
VII. Gradually ease the pole down until at least 2 nuts can
be adequately engaged, taking care not to damage the
threads. Do not lower further - first, slew a little to the
right to bring the pole vertical.
VIII. Lower onto all holding down bolts and adjust levelling
nuts to ensure correct pole alignment.
IX. Fit the top set of nuts. Unless specified otherwise, all
nuts are to be tightened to ‘Snug Tight’” as described
in clauses 9.2 & 15.2.5.2 NZS3404 (1997) (Snug tight is
the tightness that can be achieved by a person using
a standard length, 450mm, Podge spanner or by a few
impacts from an impact wrench).
X. After tightening to snug tight, the top nuts are to be
loosened, and then retightened back to snug tight (this
process ensures the Galvanized layers on the fasteners
has been compressed).
XI. Finally grout under the base using a non shrink grout
(SIKA GROUT 212 or equivalent) unless specified
otherwise
Note:
• Avoid sudden movements during lifting procedure, as this
may cause sections to become loose (if lap joints are not
fully tight) or may cause local buckling at the attachment
point
• Care is required in selecting the location of the lifting point
with columns that have proportionally large attached mass
at, or near the top of the column.
9) Erection procedure - ground planted columns and columns completed with ground stubs
The depth of the ground-planted section is nominally equal to
1/6th of the total length of the column or 1/5th of the nominal
mounting height of the column (height above ground level). In
case of streetlight columns this is the vertical distance to the top
of the outreach.
CSP Pacific recommends the following:
• Unpainted ground section - use of low grade concrete as a
backfill material.
• Painted ground section - use of low grade concrete or
granular backfill.
I. The minimum diameter of the planting hole is equal to the
across the flats (AF) dimension of the column at the bottom
of the planted section plus 200mm.
II. Backfill the hole in layers of up to 150mm each and compact
each layer individually.
III. Finish the backfill in a conical shape (See fig. 8)
Notes:
• Ground planting requirements for most Oclyte™ columns
will be covered by the above recommendations however,
responsibility for determining the required ground planting
details rests with the user. This is due to the large number of
variables including diameter of the column, number and size
of the attachments, wind conditions, soil conditions and the
type of backfill material used
Assembly and installation instructions
FIGURE 7.
24
OclytetM
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• Avoid using soil for backfilling as it may cause corrosion
• When concrete is used as a backfill, allow sufficient time for
it to set (as per the concrete suppliers instructions) before
loading
10) Plumbing in warm weatherIn warm and hot weather poles become hotter on the side facing
the sun. Due to thermal expansion differences a temporary
curvature of the pole could occur, which can be best seen by
viewing the pole from the end. Pole plumbing in such weather
conditions should be done early or late in the day.
FIGURE 8.
GEAR OPENING
EPOXY PAINTED STRIP
150×75 CABLEENTRY HOLE
SELECTED GRANULAR BACKFILLMINIMUM HOLE DIAMETERPOLE BASE WIDTH +200mm
HOLE Ø =POLE WIDTH +200mm
GR
OU
ND
PL
AN
T D
EP
TH
AS
PE
R R
EC
OM
ME
ND
AT
ION
S10
010
0
CSP PACIFICSTREETLIGHTING COLUMN
CSP PACIFICSTREETLIGHTING COLUMN
GROUND LEVEL
FIGURE 8.
GEAR OPENING
EPOXY PAINTED STRIP
150×75 CABLEENTRY HOLE
SELECTED GRANULAR BACKFILLMINIMUM HOLE DIAMETERPOLE BASE WIDTH +200mm
HOLE Ø =POLE WIDTH +200mm
GR
OU
ND
PL
AN
T D
EP
TH
AS
PE
R R
EC
OM
ME
ND
AT
ION
S10
010
0
CSP PACIFICSTREETLIGHTING COLUMN
CSP PACIFICSTREETLIGHTING COLUMN
GROUND LEVEL
Assembly and installation instructions
25
Shear base polesShear base (Slip Base) poles are a very effective way to reduce the probability of severe injury to vehicle occupants.
A characteristic of shear base poles is that, when impacted at normal urban operating traffic speeds, they are generally dislodged
from their original position.
To ensure that a shear base pole performs in the designed manner, it is important that the pole be installed correctly.
• Alignment of the shear base flange to the traffic flow should
be as per diagram 2. Ensure that the flange is levelled.
• The ground stub should be backfilled with concrete to the
outside ground level using 17.5MPa concrete. To delay
corrosion, concrete can be put on the inside of the ground
stub. However, if concrete is placed inside the ground
stub, it is very important that the level should be just below
the drainage holes near the top of the stub, with the top
mounded to aid in water drainage. This prevents water from
permanently sitting inside the stub, leading to accelerated
corrosion – see diagram 1. Ensure that the top face of the
flange is cleaned of any concrete following pouring.
• Prior to erection ensure that all components are present and
clean - diagram 4.
• Position the tab washers on the lower flange and ensure that
the tabs are correctly engaged inside the inner edge of the
flange. This is critical to the functioning system.
• Position the pre-assembled pole over the ground stub
flange, ensuring that the tab washers are not knocked out
of alignment.
• Terrain in the vicinity of the shear base ground stub must
be graded to allow a vehicle to pass over the stub without
interference, and also to avoid the vehicle becoming
airborne prior to impacting the column. Generally a negative
slope of 1:6 should not be exceeded. The ground stub
should not protrude more than 75mm on horizontal ground
conditions or 100mm above the ground line over a horizontal
span of 1.5m - see diagram 1 and 3.
• Lubricate the M24 x 110mm bolts with a suitable lubricant
such as Loctite™ Heavy Duty Anti-Seize stick, Loctite™
Silver Grade Anti-Seize Lubricant pouch or Holts Lube
Stick. Ensure that all parts of the thread are covered.
For easy installation insert the bolts so that the nuts are
facing upwards, see diagram 4 and then tighten to 250Nm
minimum torque. Slacken off and re-torque to 90-
100Nm immediately or, at the very least, before the
road is opened. If the bolts are left tighter than about 90-
100Nm, the shear base will not perform as required in the
event of being struck. Correct alignment of all components
should be checked at this stage. Using locknuts is also
recommended.
• The shear base connection is to be inspected every 6
months, or after significant weather events (severe wind
speeds). Each bolt is removed, checked for condition
(fatigue cracking, corrosion etc.) and then re-installed as
per previous assembly notes. If there is any sign of fatigue
damage to the bolt, the bolt must be replaced. Adequate
column supports or baseplate clamps must be provided
during the inspection process.
GROUND LEVEL
CABLE ENTRY HOLE
SHEAR BASE ASSEMBLY
17.5 MPa CONCRETE BACKFILL IN 200MM MINIMUM OVERSIZE HOLE
MOUND CONCRETE INSIDE GROUND STUB TO UNDERSIDE OF DRAIN HOLES
GROUND STUB
STREETLIGHTING COLUMN
75
BOLT TORQUE
250Nm PRE-TORQUE90 TO 100Nm FINAL6 MONTHLY INSPECTION
DIAGRAM 1
STREETLIGHTING COLUMN
SHEAR BASE ASSEMBLY
GEAR OPENING
GALVVENT HOLE
DIAGRAM 2
NOTCH FOROUTREACH DIRECTION
DIRECTION OFOUTREACH
DIR
EC
TIO
N O
FT
RA
FFIC
FLO
W
15º
6 MAX. GROUND LEVEL1:6 MAXIMUM
NEGATIVE SLOPE
1500 SPAN
100m
mM
AX
IMU
M
1
DIAGRAM 3
Shear base assembly, installation and maintenance
26
OclytetM
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Diagram 4
Shear base assembly, installation and maintenance
27
Oclyte™ Tuff Coat™ is a high-performance, two-component Polyurethane spray coating that is field proven world wide for extending the service life of utility poles beyond the life expectancy of conventional galvanising.
It is specifically engineered to add corrosion, abrasion and
impact resistance to galvanised steel structures such as:
utility poles, multiplate structures and guardrail components –
especially at and below ground level.
Features
• Direct to metal application – no primer required with
application to mechanically prepared (profile shaping)
galvanised or steel substrates
• Green technology – 100% solids technology, contains no
VOCs (Volatile Organic Compounds – e.g. paint solvent),
styrene or coal tar
• Single coat – is applied in a single coat with a multi-pass
application to create the required film builds and is five times
thicker than the currently used paint system
• Superior scratch and impact resistant – due to an
extremely durable polymer membrane, damage is highly
unlikely during handling and/or installation
• Chemical resistance – provides exceptional chemical
resistance to a wide range of aggressive soils, salts and
other chemicals
• Fast cure – 10 minutes to handle
• CSP Pacific offers a 20 year system warranty
Performance testingThis product has been thoroughly performance tested for:
• Toughness
• Impact
• Scratch resistance
• Chemical resistance
• Corrosion resistance
• Adhesion
• Cathodic disbondment
• Salt spray resistance
In addition CSP Pacific has undertaken comparative
‘accelerated corrosion testing’ between the various coating
systems available on the market and the currently used system
See test results, where corrosion was simulated over time.
Optional corrosion protection Oclyte™ Tuff Coat™
28
OclytetM
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Optional corrosion protection Oclyte™ Tuff Coat™
Comparative accelerated corrosion test resultsThese tests simulated potential damage during installation and handling by scratching the coating on the test pieces down to bare
metal. The coating was monitored over time at the scratched area and the undamaged area.
NB – A saw was required to cut through the Oclyte™ Tuff Coat™ to expose the metal during testing
Hot Dip Galvanising after 500 hours of salt spray testing
Hot Dip Galvanising after 1000 hours of salt spray testing
Result
• Galvanising has sacrificed itself to protect the steel
• After 1000 hours of salt spray testing almost all the
galvanising was gone
Oclyte™ Tuff Coat™ after 500 hours of salt spray testing
Oclyte™ Tuff Coat™ after 1000 hours of salt spray testing
Result
• Excellent adhesion to the surface
• 5-10mm loss of adhesion at the cut surface area only
• 4mm start of corrosion at the cut area
• Uncut surface is in excellent condition, no corrosion present
29
Standard ground plantedNotes
30
OclytetM
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31
www.csppacific.co.nz
CSP Pacific – A Fletcher Concrete & Infrastructure Limited business
306 Neilson Street, Onehunga, Auckland 1061, New Zealand PO Box 12 949, Penrose, Auckland 1642, New Zealand
Ph: 0800 655 200 or +64 9 634 1239 Fax: +64 9 634 4525
Copyright and Limited Reproduction:
The design of and all content appearing in this brochure are the copyright of CSP Pacific. No part of this brochure may be:
• distributedorcopiedforanycommercialpurpose,norincorporatedinanyotherworkorpublication(whetherinhardcopy, electronic or any other form); or
• resold,published,copied,reproduced,transmittedorstored(includinginanyotherbrochuresorotherelectronicform)exceptthatyoumayprint,orcopyonlyforyourownuse(orforuseinanydocument,proposalorpresentationfor the purpose of specifying products manufactured or supplied by CSP Pacific), without the express permission of CSP Pacific.
Disclaimer:
This Brochure contains files which were current at the time of printing. Latest drawings and information are available in PDF format from our website www.csppacific.co.nz