4. GENERAL REQUIREMENTS The design, fabrication, processes, tolerances,and inspection of poles shall conform to the following:

4.1 Design Requirements:**4.1.1 Pole designs shall be prepared from the attached configurationdrawings, design loads and strength requirements for the standard class poles.Poles shall be designed by the ultimate strength method as explained in ACI 318.The point-of-fixity shall be considered to be located at a distance from thepole butt which is equal to 7% of the pole length. The pole shall besymmetrically designed such that the strength required in any one directionshall be required in all directions about the longitudinal axis. The poles shallbe uniform taper from tip to butt.
**4.1.2 Using the corresponding values in Table 1, the poles shall bedesigned for the following requirements as illustrated by Figure 1:

a. The reinforcing steel shall begin at the pole tip and the pole shall    develop the minimum ultimate moment capacity required in Table 1 at a    distance of five feet from the pole tip;

b. The pole shall develop the minimum ultimate moment capacity along the    pole to the point-of-fixity which is calculated by multiplying the tip load    in Table 1 by the distance from the tip load;

c. The reinforcing steel required at the point-of-fixity shall continue    to the pole butt.
**4.1.3    The poles shall be designed to withstand the specified tip loading without    exceeding a pole deflection of 15 percent of the pole height above the point    of fixity when tested under short term loading conditions in accordance with    the horizontal test procedures described in the Guide for the Design of    Prestressed Concrete Poles (ACSE/PCI Joint Committee on Concrete Poles).
**FIGURE 1

Minimum Ultimate Moment Capacity Diagram along the Pole**** 

4.1.4  The poles shall be designed to withstand 40 percent of the specified tip  loading without exceeding a pole deflection of  5 percent of the pole height above the point of fixity when tested under long  term loading conditions in accordance with the horizontal test procedures  described in the Guide for the Design of Prestressed Concrete Poles (ACSE/PCI  Joint Committee on Concrete Poles).
**4.1.5    Poles shall be designed so that the cracking strength of the pole exceeds 40    percent of the required ultimate strength.
**4.1.6    Poles shall be designed so that the zero tension strength of the pole    exceeds 28 percent of the required ultimate strength.
**TABLE 1

Strength Requirements**

Standard Class      Designations For Spun Concrete Poles

Minimum      Ultimate Moment Capacity At Five Feet From Pole Tip (Ft.-Kip)

Tip Load      (Lbs.)

C-12.0
96
12,000
C-11.0
88
11,000
C-10.0
80
10,000
C-09.0
72
9,000
C-08.0
64
8,000
C-07.1
57
7,125
C-06.2
50
6,250
C-05.4
44
5,450
C-04.7
38
4,700
C-04.0
32
4,000
C-03.4
27
3,375
C-02.8
23
2,825
C-02.3
19
2,325
C-01.9
15
1,875**4.1.7 Poles shall be designed to withstand a one-point (tilting) pickupduring erection. The poles shall be designed for two-point pickup for horizontalhandling. Poles shall be designed for the loads generated from handling anderecting without exceeding the cracking moment capacity of the poles.
**4.1.8 The pole design shall include allowances for loads from handling,transportation and erection without failure, permanent deformation, or damage tothe pole when handled according to the manufacturer's instructions. (See Section6.1)
**4.1.9 The design of each pole shall be performed using the applicablecodes and standards listed in Section 3 of this specification.

**4.1.10** Pole design and design calculations shall be the responsibilityof the manufacturer.
**4.2 Materials:
4.2.1 The chemical properties ofmaterials used in the manufacture of the poles shall meet the requirements ofthe applicable ASTM specification and be such that noticeable pyrite staining orefflorescence due to sulfates and/or chlorides does not occur.**4.2.2 All anchors and inserts provided by the manufacturer shall be hotdip galvanized or noncorrosive material. Cadmium-plated and aluminum materialshall not be used. All inserts shall be noncorrosive materials designed andmanufactured for the intended purpose and used according to manufacturer'srecommendations. If the manufacturer considers lifting devices necessary ordesirable, suitable flush inserts may be cast into the pole with removablelifting attachments.
**4.2.3 The concrete shall have a minimum 28-day compressive strength of5,000 psi with a maximum water-cement ratio of 0.40. Higher strengths andlower water-cement ratios are encouraged and may be necessary to offset steelcover requirements.
**4.2.4 The cement shall be either Type I, II, III, or V Portland cementconforming to ASTM C150.
**4.2.5 Fine aggregate shall be a natural sand, consisting of clean,strong, hard, durable uncoated particles conforming to ASTM C33, and allspecifications included therein. The aggregate shall be well graded from No. 4to No. 200 sieve. Deleterious substances shall not comprise more than5 percent of the sample.
**4.2.6 Coarse aggregate shall be clean, tough, crushed stone conforming toASTM C33, and all specifications included therein. The aggregate shall be wellgraded from a 3/4 inch to a No. 8 sieve with no more than 5 percent of thesample passing through a No. 8 sieve. Deleterious substance content shall notexceed 5 percent of the sample. Resistance to abrasion shall not exceed40 percent as tested in conformance with ASTM C131. Absorption shall beless than 4 percent or aggregate shall be saturated with water prior to use inconcrete.
**4.2.7 Aggregate shall be tested in accordance with ASTM C289 to determinean alkali-aggregate reaction. Crushed rock or partially crushed rock shall bethe source of the aggregate.
**4.2.8 Water shall be clean, free from undesirable amounts of oils, acids,alkalis, salts, organic materials, or other deleterious substances.
**4.2.9 Admixtures shall conform to ASTM C494. Air entraining admixturescan be used if approved by the owner. Admixtures shall not contain chloride ionsin quantities that would cause the total chloride content of the concrete toexceed 0.4 pound per cubic yard.
**4.2.10 Prestressing steel mechanical properties, reinforcing steel andspiral reinforcement shall be in accordance with the applicable ASTMspecifications listed in Section 3 of this specification.
**4.2.11 Concrete mix design requirements listed above can be altered withthe owner's approval.
**4.3 Workmanship:
4.3.1 The pole shall be circular in cross section and the diameter, as  measured at any location on the pole, shall not vary by more than  1/4 inch from any other measurement taken on that cross section.
**4.3.2 The pole shall have a uniform taper from top to butt.
**4.3.3 Deviation of the pole from straightness is allowed in one plane andone direction only. A straight line joining the edge of the pole at the butt andthe edge of the pole at the top shall not be further from the surface of thepole at any point by more than the accumulated value of 0.25 inches for each 10feet of length between the two ends. The detensioning operation shall beperformed in a manner to keep the prestressing forces symmetrical.
**4.3.4 Prestressing steel stress limits shall not exceed:
- 80 percent of the ultimate strength or 94 percent of the yield        strength or the maximum value recommended by the manufacturer of        prestressing steels or anchorages for jacking force;  
- 74 percent of the ultimate strength or 82 percent of the yield        strength immediately after prestress transfer; and  
- 70 percent of the ultimate strength for post-tensioned steel at        anchorages and couplers immediately after anchorage.
**4.3.5 Spiral reinforcement shall cover the entire pole length. The  minimum clear spacing of spiral reinforcement in the top 2 feet and bottom 2  feet of the pole shall be 4/3 of the maximum coarse aggregate or three times  the strand diameter, whichever is larger, but not less than one inch. The  maximum clear spacing for the remainder of the pole shall not exceed 4 inches.
**4.3.6 Clear distance between prestressing steel strands shall be either4/3 times the maximum aggregate size or 3 times the strand diameter, whicheveris larger. In the event that this condition is not met at the pole tip, closerspacing would be permitted provided that the placement of concrete can beaccomplished satisfactorily, adequate stress transfer can take place, andappropriate provisions are used for maintaining spacing between the prestressingsteel strands.
**4.3.7 The manufacturer shall provide holes through each pole as specifiedon the pole framing drawing(s), included asAttachment A. Preformed holes shall be cast using rigid PVC inserts (or othersuitable material) held firmly in place. Plugs may be used with the owner'sapproval. Preformed inserts shall be sized for the specified hole diameter andshall be full length of pole diameter for all through holes. Unless otherwisenoted on the drawings, holes shall be perpendicular to and pass through thecenterline of the pole.
**4.3.8 The pole manufacturer shall provide preformed inserts at twolocations to allow air circulation within the pole. Inserts shall be 1 inchminimum diameter and shall have a louvered opening. The inserts shall be locatedwithin 10 feet of the tip and within 10 feet above the groundline.
**4.3.9 Holes may not be drilled through the pole wall, except asspecifically necessary to correct errors or omissions and only if approved bythe owner.
**4.3.10 The longitudinal steel shall not be cut for any reason unlessapproved by the owner. The owner may reject any pole in which the longitudinalsteel is cut. All exposed steel resulting from drilled holes shall be coveredwith an epoxy paste perASTM C881 Type III. Areas with moderate or severe spalling shall be cleaned andreformed with an epoxy paste or epoxy concrete per ASTM C881 Type II.
**4.3.11 The owner shall have the right to reject any pole in which theperformance of a bolted connection may be reduced due to the lack of a cleanlypreformed or drilled hole.
**4.4 Manufacturing Tolerances:
Manufacturing tolerances shall be limited to the following:
**Pole                length      �2 inches, or �1 inch �1/8 inch per 10 feet of length, whichever is      greater (i.e. - 120 foot pole shall have a length of 120 feet �2�      inches)      -6 inches or +12 inches for assembled spliced structure
Pole Diameter
�1/4 inch
Wall Thickness
1/4 inch or 12 percent of wall thickness. (Note: this requirement may      be waived provided that the structural adequacy and durability are not      impaired.)
Pole End Squareness
�1/2 inch per foot of pole diameter
Pole Sweep
1/4 inch per 10 feet of pole length
Pole Weight
�10 percent of calculated value
Location of Longitudinal Reinforcement
+1/4 inch and �1/8 inch reinforcement placement for the centroid of a      group
Location of Spiral Reinforcement
�25 percent of clear spacing required with total reinforcement      placement required quantity per 3 feet of pole length maintained.
Location of Group of Bolt Holes from Top of Pole
�2.0 inches
Location of Bolt Holes Within a Group of Bolt Holes
�1/8 inch
Location of Centerline Between Groups of Bolt Holes
�1.0 inch
Bolt Hole Diameter
�1/16 inch of specified diameter
Bolt Hole Alignment
Not to vary from the longitudinal pole centerline of that group of      holes by more than 1/8 inch
Location of Identification Plate
�2.0 inch
4.5 Grounding:**4.5.1 An external pole ground wire shall be used. Threaded inserts forattaching ground wire clips that hold the external ground wire shall be sized and positioned per the attached drawings.
**4.5.2 Except for bonding of the steel tendons, there shall be no internalpole grounds. A minimum of one longitudinal steel strand shall be bondedelectrically to a threaded bronze insert at the top and bottom of the pole. Eachbond shall be located within the top 2 feet of the pole top and at 4 feet abovegroundline (See Attachment A). For spliced poles an additional bond shall beprovided above and below the splice to a threaded bronze insert within 24 inchesof the splice. Steel splice sections shall have the appropriate number ofgrounding attachments. This bonding system shall be noncorrosive and shall beapproved by the owner.
**4.5.3 If required by the owner, manufacturer shall provide ground wireclamps for all ground wire attachments.
**4.6 Climbing Devices:
4.6.1 Clips for removable ladders shall begin not closer than 3 feetabove ground for a direct embedded pole and extend to the top of the pole. Eachladder clip shall be designed to support a minimum 1,000 lb. shear working load.Ladder clips shall be located to avoid interference between ladders and otherattachments.
**4.6.2 Removable step bolts shall be provided with spacing as indicatedbeginning 8 feet above groundline and extending to the structure top. Each steplug and step bolt shall be capable of withstanding a minimum of a 500 lb.working load. Step bolt mounting nuts shall be spaced at1 foot 6 inch intervals and oriented to provide maximum ease ofclimbing.
**4.7 Inserts:
4.7.1 Inserts shall be made of materials which will not deteriorate inthe environment in which they are placed. The insert shall be made of materialsthat will not react unfavorably with the concrete or fasteners. The insert shallnot be made of materials that will corrode and stain the concrete.
**4.7.2 Inserts shall not fail before the pole reaches ultimate strength,unless permitted by the owner.
**4.8 Cover:
4.8.1 There shall be a minimum of 3/4 inch of clear concrete cover overall longitudinal reinforcement and all spiral

reinforcement as a result of the concrete spinning process. Poles not meetingthis requirement shall be rejected except as allowed by Section 4.8.2.
**4.8.2 There shall be a minimum specified wall thickness of 2.5 inches ofspun concrete at all points along the pole.
**4.8.2.1 An actual wall thickness of less than 2.5 inches of spun concretemay be allowed from the pole tip to 3 feet below the pole tip provided the coverrequirements of Section 4.8.1 are met in the spinning process and provided thepole can meet all other requirements of the specifications.
**4.8.2.2 The owner shall, as soon as possible, be notified of any poleswith less than 3/4 inch of spun concrete inside cover within 3 feet of the poletip. At the owner's sole discretion, the owner may reject the pole or may allowthe pole to be repaired by swabbing the interior with an epoxy liner (per ASTMC881 - Type V, Class B or C) and plugging with 3,000 psi. concrete to theowner's satisfaction to a distance of 42 inches from the tip. No pole shallbe plugged or considered for acceptance by the owner unless assurance is made bythe manufacturer that the repaired pole can meet all requirements of thisspecification.
**4.9 Splices:
4.9.1 Flange-bolted or slip-joint type of splices are permitted. Whenrequired, flange-bolted type splice shall be used at guyed structures.
**4.9.2 The reinforcing steel and connection apparatus comprising thesplice shall be properly anchored as part of the pole. The pole shall bedesigned to fail before the splice fails by yielding of the splice steel.
**4.9.3 The axis of the pole shall not be distorted after the pole ismated. Shims shall not be used to straighten the pole unless approved by theowner. The owner reserves the right to reject a pole based on the impropermating of a pole splice.
**4.10 Appurtenances:
4.10.1 Appurtenance material shall be supplied by the owner. The ownershall also provide the manufacturer of the connectors and/or members with thelocations, orientations, sizes, types, and strength capacities of theappurtenances.
**4.10.2 The concrete pole manufacturer is responsible for the proper design coordination and fit up of all appurtenance connections andmembers to the pole(s). Manufacturer shall notify owner if any appurtenancematerial supplied by owner will not result in properly designed structure.
**4.11 Finishing:
4.11.1 The surface of the pole shall have a smooth finish with nounsealed cracks. Cracks shall be sealed either by use of an epoxy injectionsystem following the epoxy manufacturer's specifications, or by V-notching thecrack on a 1:1 slope to a minimum depth of 1/4 inch, then filling the V-notchwith an epoxy seal per ASTM C881 Type IV. Covering the crack with an epoxycoating is not allowed.
**4.11.2 Small cavities caused by air bubbles, honeycomb spots, or othersmall voids, shall be cleaned thoroughly, saturated with water and thencarefully pointed with a cement mortar. A small cavity is defined as one notlarger than 1/2 inch in diameter or deeper than 1/4 inch.
**4.11.3 If any cavities or voids absorb water which indicate the voidextends into wall of the pole, then the pole shall be rejected.
**4.11.4 The manufacturer shall seal both ends of the pole and protect thesteel strands from corrosion using a suitable epoxy. The system used shall beapproved by the owner.
**4.11.5 The center void at the top end of the pole shall be sealed with aminimum 6 inch thick 1000 psi strength concrete plug and the pole tip capped.The pole tip cap shall be a suitable epoxy-aggregate mortar securely bonded tothe pole, or shall be a metal or polymer cap securely held in place with setscrews. Sharp edges shall be tooled to form smooth, chamfered corners. Themanufacturer shall assure that the capping method will prevent weather intrusioninto the pole and prevent pole tip deterioration.
**4.11.6 The center void at the bottom end of the pole shall be sealed witha minimum 12 inch thick 1000 psi strength concrete plug. The plug shall besecurely bonded to the pole and shall be tooled to form a smooth, uniformbearing surface. A PVC formed hole shall be provided in the center of the plugto allow for drainage.
**4.11.7 Where application of epoxy-aggregate mortar is specified, thesurface of the pole where the mortar is to be applied shall first be coated withthe epoxy coating. This coating shall be allowed to cure to a tacky, but not hardened state, before the mortar isapplied. After the mortar has been applied and allowed to cure for 24 hours, atop coat of epoxy coating, 5 mil thick, shall be applied over the mortar and thesurrounding area of the pole.
**4.12 Marking:
4.12.1 Each pole shall be identified with the manufacturer'sidentification plate. The following information shall be stamped into the platewith letters not less than 1/4 inch in height:
- Manufacturer's name
- Day, month, and year of manufacture
- Structure number
- Length and class of pole
- Ultimate moment capacity at groundline
- Pole framing designation (per framing guide) or pole type
- Owner's name
**4.12.2 The manufacturer's identification plate shall be fabricated from anoncorrosive, nonstaining metal such as bronze, brass, Series 300 stainlesssteel, or an aluminum alloy that will not react unfavorably with concrete. Theplate shall have suitable anchor or anchors welded to the back of the plate topermit bonding to the pole.
**4.12.3 The identification information listed above may be cast into thesurface of each pole. These marks shall be at least 3/4 inch in height and 1/8inch deep.
**4.12.4 The identification plate or cast in-place markings shall belocated on an in-line face of the pole in the direction of the transmissionline. The bottom of the identification plate or last line of the cast in-placemarkings shall be located five feet above the defined groundline.
**4.12.5 Each pole shall be marked with the information listed below. Apermanent marker shall be used and the writing shall be small but legible. Forspliced poles, each section shall be marked as below:
- Support points;  
- Two-point pickup location for handling the pole in the horizontal        position;  
- One-point pickup location for use in raising the pole to a vertical position and handling during the setting operation;  
- Pole length and class, fabrication number, structure number, and        pole framing guide number on the butt of the pole; and  
- Cant hole locations, if required by owner.**************************************************************************************************************************