The Comprehensive Guide to Light Pole Manufacturing and Installation

Light poles are a common sight, especially in outdoor public areas. They are an essential part of our daily travels, making them constantly in demand, whether for new construction projects or as replacements for older poles.

The process of manufacturing light poles depends on several factors. First, it varies based on the material used for construction. Second, it depends on the type of application and installation required.

This article provides an overview of the key aspects of light pole production.

Light Pole Materials

Not all light poles are made the same, and their composition determines their suitability for different applications. Each material has its advantages and disadvantages, including cost, durability, and safety.

• Steel

Steel is the most commonly used material for light poles due to its strength and durability. It can withstand high winds and support multiple attached fixtures. However, steel is conductive and susceptible to rust and corrosion.

• Aluminum

Aluminum light poles are strong yet lightweight. They are resistant to rust and corrosion, making them ideal for coastal areas. They also have a long lifespan of over 50 years, reducing the need for frequent replacements. However, aluminum poles are not as strong as steel and come at a higher initial cost, though their longevity provides a worthwhile return on investment if they can support the required fixtures.

• Fiberglass (Composite)

Fiberglass light poles are both strong and lightweight. They are non-conductive and resistant to rust, corrosion, and harmonic vibration. While they last longer than steel (typically 20–30 years), they do not outlast aluminum poles. Fiberglass poles are also the most expensive option.

• Wood/Concrete

Although wood and concrete poles are common, this discussion focuses on steel, aluminum, and fiberglass options.

Light Pole Installation

There are two primary types of light pole installations: direct burial and anchor-based.

• Direct Burial Light Pole

Direct burial light poles are installed by inserting them directly into the ground without the need for a concrete base or anchor bolts. Aluminum and fiberglass poles are typically used since they are resistant to corrosion.

This installation method is more affordable and straightforward than anchor-based installations, but the poles need to be taller to account for the underground section. However, direct burial is not suitable for loose sand or soil, and replacing buried poles can be more expensive and time-consuming.

• Anchor-Based Light Pole

Anchor-based light poles are installed by securing them to a concrete foundation with anchor bolts, nuts, and washers. These poles have a base plate welded to them for attachment to the concrete. While they require more effort and cost to install initially, they are easier to replace and can withstand impact from vehicles.

Light Pole Components

Before delving into the manufacturing process, it's important to understand the key components of a light pole:

• Handhole/Cover: Located near the bottom of the pole, it provides access to internal wiring and is covered by a tamper-proof plate.

• Conduit Hole: Positioned near the base, it allows electrical wiring to run inside the pole.

• Base Covers and Plates: Steel and aluminum poles have welded base plates, while fiberglass poles use epoxy to attach them. Base covers conceal anchor bolts for safety and aesthetics.

• Pole Caps: These cover the top of the pole if no fixtures are mounted, preventing rain and birds from entering.

• Anchor Bolts, Nuts, and Washers: These secure anchor-based poles to their concrete foundation and vary in size based on wind conditions, pole height, soil type, and fixture weight.

• Grounding Provision (Steel, Aluminum): Required for safety, this grounding mechanism prevents electrocution, typically using a lug nut connected to a copper stake.

Light Pole Manufacturing Process

The manufacturing process varies depending on the material used. Here is a general overview of how different light poles are made:

Steel

1. A flat steel sheet is cut to the required dimensions.

2. The sheet is rolled into a tube using cold rolling or a brake press to achieve a round or square shape.

3. Handholes and mounting holes are cut using a laser or plasma cutter.

4. A base plate is cut, positioned on the tube, and welded at the top and bottom.

5. The pole undergoes finishing treatments such as painting, powder coating, or galvanizing.

Aluminum

1. Molten aluminum is poured into a mold that shapes the pole shaft.

2. The aluminum is extruded into the required size and shape.

3. The base plate is either cast or cut from a sheet and welded onto the shaft.

4. Handholes and mounting holes are cut.

5. The pole is either anodized or powder-coated for durability.

Fiberglass

1. Fiberglass strands are wound into cords and dipped in polyester resin.

2. These cords are wrapped around a mandrel, shaping the pole.

3. The mandrel spins to control the pole’s strength and structure.

4. Steam curing solidifies the resin, and the pole is removed from the mandrel after a few hours.

5. The pole is sanded, and excess material is removed from both ends.

6. Fixture mounting holes, handholes, and conduit holes are cut using an automated router.

7. Base plates are attached with epoxy for anchor-based poles.

8. The pole is powder-coated or painted.

Light Pole Finishes and Treatments

Once light poles are manufactured, they undergo various finishes and treatments:

• Powder Coating (Steel and Aluminum): A dry powder finish is baked onto the pole for a tough, long-lasting protective layer.

• Galvanizing (Steel): The pole is dipped in zinc to prevent corrosion. A steel pole can be both galvanized and powder-coated.

• Anodizing (Aluminum): An electrolytic process adds a corrosion-resistant oxide layer to the aluminum surface. This process changes the color of the pole, so the desired color must be chosen before anodizing.

BEYOND LED Technology’s In-House Manufacturing

BEYOND LED Technology operates in-house manufacturing facilities that prioritize quality and efficiency. This enables faster distribution, greater control over the production process, and the ability to deliver high-quality products. With stocked inventory and express production capabilities, BEYOND LED Technology ensures quick & instant shipping and reduced lead times for steel light poles.

By leveraging expert craftsmanship and advanced manufacturing techniques, BEYOND LED Technology continues to provide reliable, durable, and high-performance lighting solutions for a wide range of applications.