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Oclyte™ Modular Octagonal Steel ColumnsProduct & Installation Manual

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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


50

5

247025º


(STANDARD TILT - OTHER TILTS ARE ALSO AVAILABLE) 15

1843

30

282

1

0

SEE DETAIL A

DETAIL A

BUTT WELD

SECTION 1


50

5

247025º


(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


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.


22

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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


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


FIGURE 7.

24

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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


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



GROUND LEVEL


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


26

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Diagram 4


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.


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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

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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

Oclyte Modular Octagonal Steel Columns Product ... · PDF fileOclyte™ Modular Octagonal Steel Columns ... The Oclyte™ modular steel column is now a familiar ... ensures long service

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