l_s-‘2c 

US Deportment 

0fTronspotroti 

Federal Highway 

Administration Refer to: HNG-14 

Fouad H. Fouad, PhD., P.E. 

Sherman International Corp. 

Pole Division 

2117 Magnolia Avenue So., Suite 103 

Birmingham, Alabama 35205 

Dear Dr. Fouad: 

Thank you for your letter of April 24 to Mr. Thomas 0. Willett requesting 

federal Highway Administration's (FHWA) acceptance of your company's new line 

of breakaway fiberglass poles. You enclosed product specifications and a 

report, dated February 1992, of pendulum testing performed by the Southwest 

Research Institute (SWRI). In response to our requests, you sent additional 

material on the extrapolated high speed velocity change on May 21 and June 3. 

One test was conducted to assess the compliance of the Sherman Catalog Number 

D-MB39-F-50-SlO direct burial fiberglass luminaire support with the breakaway 

requirements of the 1985 AASHTD Standard Specifications for Structural 

Supports for Highway Signs, Luminaires and Traffic Signals. These 

specifications have been adopted, with minor modifications, by the FHWA. The 

test article is described in the enclosed specifications and drawing, and is 

considered representative of the largest of the breakaway direct burial poles. 

The new breakaway design is achieved by weakening various layers of the 

fiberglass mats as well as adding a bondbreaker between the layers during 

fabrication of the pole. The pole is also strengthened above and below the 

impact zone with additional glass reinforcement. This breakaway design will 

supersede Sherman's previous direct burial fiberglass poles which received 

FHWA acceptance via our letter of November 10, 1988. We understand the 

special designation "85BK" will be given to your company's new line of 

breakaway poles so that they may be easily differentiated from non-breakaway 

models. 

The test results are sunarized here: 

Soil type 

Pole Mass, Kg (lbs.) 

NCHRP 230 S-2 ("Weak") soil* 

112 (246.5) 
2

Luminaire Mounting Height, m (ft.) 11.28 (37.0)

Mass of Pole, Mast Arm, and Luminaire

m point of breakaway, kg (lbs.) 106.8 (235.0)**

Pendulum Mass, kg (lbs.) 818 (1,800)

Impact Speed, km/h (mph) 32.2 (20.0)

Velocity Change, m/s (fps) 2.04 (6.69)

Calculated High Speed Velocity

Change, m/s (fps) 1.75 (5.73)

Stub Height mm (in.) 250 (9.8)***

*Testing in S-2 soil is considered a "worst case" for the device, thus testing

in S-l soil is not warranted.

**Mass of pole below point of breakaway is 35.7 kg (78.5 lbs.)

***The stub of the pole (which was pulled up out of the soil a few inches)

was severely damaged and had lost its structural integrity. It did not

snag, nor otherwise impede a car driven over it after the test.

These results meet the change in velocity and stub height requirements adopted

by AASHTO and the FHWA. Therefore, your company's fiberglass pole described

above is acceptable for use on Federal-aid highway projects, within the range

of conditions tested, if proposed by a State. You also asked for our

acceptance of several other poles which would be expected to perform at least

equal to the tested pole with respect to vehicular impact. A listing of the

catalog numbers and sizes of these poles are enclosed. We concur that these

additional poles are also acceptable for use on Federal-aid highway projects

as discussed above.

Our acceptance is limited to the breakaway characteristics of the system and

does not cover its structural features. Presumably, you will supply potential

users with sufficient information on structural design and installation

requirements to ensure proper performance. We anticipate that the States will

require certification from Sherman International Corp. that the poles

furnished will meet the FHWA change in velocity requirements and have . . . . essentially the same composition, mechanical properties, and geometry as that used in the tested pole (with the understanding that the basic dimensions will

differ for the additional poles accepted, as discussed above).
3

Sherman International Corp., fiberglass poles are proprietary. Thus, to be used in a Federal-aid highway project: (a) they must be supplied through

competitive bidding with equally suitable unpatented items; (b) the State

highway agency must certify that they are essential for synchronization with

existing highway facilities or that no equally suitable alternate exists; or

(c) they must be used for research or for a distinctive type of construction

on relatively short sections of road for experimental purposes. Our

regulations concerning proprietary products are contained in Title 23, Code of

Federal Regulations, Section 635.411, a copy of which is enclosed.

Sincerely yours,

Lawrence A. Staron

Chief, Federal-Aid and Design Division

Enclosures

Geometric and Roadside Design Acceptance Letter Number LS-26
TIP DIAMETEEC 

SHERMAN 

1. 

i 

37’~v NMINAL 

MOUNTING HEIGHT 

I I IlKAWN I DATE l-0731 

Figure 2. Manufacturer’s Drawing of Test Article 
Poles Submitted for FHWA Breakaway Approval

Catalog Number Nominal

Mtg Ht

0

D-MB39-F-50-S10 3 7

I as I 39.37 I 147 I 3.7 I l!c!!2 I 3 I 6.63

C-MN- Nomid Shaft Pole Butt

Mtg Ht Wgt. 0%. O.D.

0 z (LB) 0 0 Iqem

SB13-C-50 10 13.17 24 a.7 6.53 1 1.33

SB20-C-50 16 19.76 62 3.7 7.97 2 3.76

SB24-C-50 20 24.99 66 3.7 0.33 2 3.75

25 29.53 95 4.41 10.39 3 6.63

MB35-D-50-S4 30 34.69 123 4.41 11.86 3 6.63

MB39-F-50-S4 35 39.37 167 5.12 13.63 4 7.69
Catalog Number -;a$gh3b& -Pob -Tip b&t

0 Y%! wnt (LB) O=.(IN) (IN,

MB2s-pM)-D4 20 23.00 S5 4.41 9.98

bfBa&F-mD4 25 29.53 117 5.l2 lldl

MBsx%O-D4 30 34.m 158 5-&l 13.28

IulBewwD4 sa 3@.30 185 5.83 14.34

MBSO-F-50-M 28 29.56 l 115 5.l2 11.51 3 5.53

MRSS-F-50+35 30 32.88 lS5 5.l2 12.21 4 7.m

IbfBSQ-F-5&S5 98 se.42 178 5.12 13.89 4 7.50

ME23-F-50-D6 I 20 I 23.00 I 05 1 5.13 I 10.00 I 3 I 5.89

blBsoGmD6 I ~~~ 25 I 29.53 I 141 I 5.83 I l2.a I 4 I 7.m

MB33-G-59-D5 SO 32.89 161 5.83 l2.82 4 7.m

MB2&K-50-810 25 27.m 121 6.54 l2.4a 3 5.68

MB99-K-60810 SO 32.80 152 6.54 13.52 4 7.m

-7. cp;r, (LB) 0 t-IN) Layem

bIB22-K-50-DlO 20 2L50 115 a54 1118 a 5.5a

AtB21-K-5O-SI.2 20 20.75 88 a54 11.02 8 5&S

bfB%bK-5O-Sl2 25 121 a54 l2.21 a 5.69

blBS2-K-5O=Sl2 SO 31.75 170 a54 13.40 4 7.50

MB35-K-604s 35 3aoB 201 a54 14.34 4 7.50

I I I I I I I

EZWI-C-50-DIM I 20 I 22.97 I ae I 3.70 I am I 3 I 5.55

EB3O-D-5fhDE4 I 26 I 28.63 I 131 I 4.41 I 1o.m I 4 1 7.m

EB33-D-50-DE4 l 30 I 34.00 I 158 I 4.41 I 11.75 I 41 7.m

PMBS4-F-75-M l 30 I 33.m I ia3 I 5.ti I 12.36 I 47 7.m
U_Ttl36-~ZSZ xl w lV4 4.41 u.v 4 ,.pv

L

D-TBscm-!a62 26 !a68 l!u 4.41 10.3 3 6.63

- -__-

___

D-TB24-D-262 ii u 91--. 4.41 _ .- 9.6 --- s iiii

I I

Y- I--- !- . _.Y. n - m I.. , - , . , _.-

D-MBSS-D-so-s6 90 32.33 141 4.41 11.49 3 6.33

IYm!m-B-36 16 19.76 40 3.0 1.3 2 3.76

wg.m W

0 (IN) ml

-

P-

_-__ - _ _~_ I _.__ I __ __ I_- I I--. I

134.33

I I I I I I 1 DalBuw-m 35.33 39.42 136 6.12 12.70 4 7.60

D-MBss-F-6o-s6/D6 Y~eY-- 31.42 36.0 160 6.12 12.70 4 7.50 Il._ _." IVV =..a I.W u up0

DafB!m-F-rn 26.0 29.59 ll.3 6.12 11.60 3 MI!3

nurau_n_~~ma m 40 0. al A .I

D-sm60 30.92 us!2 ;r;^a 3.70 “13% ; ;.zJ

D-sB!sG60 20.0 a.0 76 3.79 3.9 2 3.16 \' 'I ,u.,

I F-,-l- NT..-L- I IT_-:-_, I OS__P I __I_ I,_ I,~.. I”, I. I
TECHNICAL INFORMATION

SPUN FIBERGLASS REINFORCED PLASTIC POLES

I MATERIALS

The two main components used in the manufacturing of the

spun FRP pole are the polyester resin and the fiberglass

fabric reinforcement. In addition a non-structural surfacing veil (mat) is used to pro:tz;eprrotion to the

surface of the pole. The type, , and some of

the physical characteristics of the basic materials used

are given herein:

(A) Polyester Resin

Type: Unsaturated polyester resin solution

Manufacturer: GLS Fiberglass m-?.rl- U=.,.,-. L LQVF *.-s . GLS lcg_2-!&JC

Viscosity: #3 60 rpm; 400-500 cps .

Unit Weight: 9.1 lbs/gallon; specific gravity = 1.10 1

Vapor Density: Heavier than air

Evaporation Rate: Slower than ether

Boiling Range: 290-295 OF

Percentage Volatile by Volume: 47.4%

Flashpoint: 9OoF ; LEL = 1.1%

Gel Time: (mm:ss) = 16:OO

Cure Time: (mm:ss) = 27:00

Peak Exotherm = 357 OF

(B) Glass Fabric

Type: "E" glass (electrical grade); undirectional roving

Manufacturer & Class: Syncoglas V672 or Syncoglas 42RK/M300

Weight: 29 oz./sq.yd.

Specific Gravity: = 2.54

Thickness: =.05 in./layer

(C) SurfAcinq Veil

Type: Polyester mat.

Manufacturer & Class:

Weight: Royalin Gmbh, G6/11.40A/00/50 ’ 1.5 oz/sq.yd.

Thickness: .019 in./layer

GLASS

20 OZ/SO YD LONGITUINALLY

ORIENTED

(70%)

* WGT - 28 OZ/SQ YD

8 DZ/SO YD. CHOPPED STRAND

MECHANICALLY

BONDED (30%)

* THICK - 50 MILS

VEIL

* WGT ~ 1.50 OZ/SCr YD ._

* THICK ~ 19 WILS :I

RESIN

* SPECIFIC GRAVITY = 1.10 (68.6 LB/ CU.FT,

9.2 LB/GALLON)

*SATURAITIoN

FOR GLASS 60% Rwy 40% GLASS BY WEIGHT I

F OR VEIL 3m

10% POLYESTER BY WEIGHT
. IS A LIGHTWEIGHT MAT (~1.5 OZ./SQ.YD.)

. USED AS RESIN-RICH SURFACE LAYER

. TO PROVIDE GOOD APPEARANCE, SMOOTH SURFACE

. F OR RESISTANCE TO WEATHERING

. PREVENTS UNDERLYING GLASS FIBERS FROM PROTRUDING THRU TH E

SURFACE

. P ROVIDES A CHEMICAL RESISTANT COVERING

. COMPENSATES FOR SHRINKAGE THAT MIGHT OTHERWISE OCCUR IN A

RESIN-RICH SURFACE

. TYPE USED:

STANDARD SURFACING VEIL MADE OF POLYESTER MA TERIA L.

. T HE VEIL IS HIGH IN RESIN (MIN 90% BY WGT) THAT CONTAINS UVINHIBITORS AND PIGMENT THAT MAKES IT UV-RESISTANT, AND

ASSURES LONG LIFE WITHOUT CLASS l BLOWING"
II MECHANICAt PROPERTIES

-L-.-I__. Listed beiow are typicai pnysrcrl and iiSCbiiiCZi pi=pEitiES

of the composite FRP laminate used in pole construction.

The properties are based on a laminate that is composed of

40% glass and 60% polyester resin.

Specific Gravity: 1.7

Tensile Strength (psi) 36,000

Compressive Strength (psi1 30,000

Flexural strength (psi) 35,000

Shear strength (psi) 6,000

Elastic Modulus (psi) 2,700,OOO

Poisson's Ratio 0.16

III MANUFACTURING PROCESS

Our manufacturing process may be summarized as follows:

11

2)

3)

4)

9)

6)

7)

A predetermined number of glass fabric layers and a

surfacing veil are placed in a hollow steel mold.

The mold is rotated slowly so the materials will

unwind and conform smoothly to the wall of the mold.

The mold is then rotated at a high speed (1200-1500

rpm) during which the polyester resin and special

catalyst are injected into the mold.

During spinning the resin is being cured using

radiant heaters which keep the mold at an elevated

temperature.

After the laminate achieves complete saturation the

speed of the mold is reduced while the resin still

continues to cure.

The finished pole shaft is removed from the mold after

completion of curing.

The shaft is then trimmed and subjected to the special

fabrication operations as required per shop drawings.

Notes on Pole Manufacturinq

i! _ss_ Thm _-__e-c ra=in/alraa =--v- fiber ratio (by weight) for,the main

reinforcing glass fabric is approximately 0.60.

2) The resin/glass fiber ratio for the surfacing veil is

approximately 0.90.

3) The resin gel time varies between 15 to 20 minutes.

4) The gel time is established and varied by con&olling

the dosage of MEKP (peroxide catalyst)

9) The curing period is approximately as long as the gel

time.
.

8 636.411 Material or product selection.

(a) Federal funds shall not participate. directly or indirectly. in payment for any premium or royalty on any

patented or proprietary material, spec- ification, or process specifically set

forth in the plans and specifications

for a project. unless: I.. ____L __.__.. 3 ~~ _~_.~*_.____ 11~ Such patented or proprietary item is purchased or obtained through competitive bidding with equally suitable unpatented items: or

(2) The State highway agency o<ies either that such Datented or Pm

prietary item ls esseniial for synchre nization with existing highway fscilities, or that no equally stiitabie alternate exlsts; or

(3) Such patented or proprletPrY Item is used for research or for a dlsfodoral Highway AdminIstration, DOT

tinctive type of construction on rela- ’ tlvely short sections of road for experimental purposes.

(b) When there is available for pur- chase more than one nonpatented. nonproprietary material, semlfinlshed

or finished article or product that will

fulfill the requirementi for an item of

work of a project and these available

materials or products are Judged to be

I

’ of satisfactory quality and equally acceptable on the basis of engineering snalysis and the anticipated prices for the related item(s) of work are estlmated to be approximately the same,

the PS&E for the project shall either contain or include by reference the

specifications for each such material

or product that is considered aecepta- ble for incorporation in the work. If the State hlghway agency wishes to substitute some other acceptable material or product for the material or

product designated by the successful bidder or bld as the lowest alternate.

snd such substitution results in an Increase in costs, there will not be Feder-

&aid participation ln any increase In Costa.

(13 A State highway agency may requlre a specific material or product when there are other acceptable materials and products, when such specific

choice js approved by the Division Administrator as being In the public in- terest. When the Division Administrator’s approval is not obtained, the item will be nonparticipatlng unless bidding Procedures are used that establish the

unit price of each acceptable altemative. In this case Federal-aid partlcipa- Man will be based on the lowest price SO established.

(d) Appendix A sets forth the -Areauirementa regarding (1) the

specification of altemklve types of culvert pipes. and (2) the number and

tYpes of such alternatives which must

be set forth In the speciflcatlons for

vsrious types of drainage installations.

te) Reference in specifications and on plans to single trade name materi- als will not be approved on Fe@eral-aid

contracts.

185
FEB I 5 1996

400 Seventh St.. S.W,

Washington, D,C. 20590

Refer to: HNG-14

Fouad H. Fouad, Ph.D., P.E.

Professor of Civil Engineering

Sherman Utility Structures, Inc

P.O. Box 1926

Birmingham, Alabama 35201

Dear Mr. Fouad:

This is in response to your letter of January 7 to Mr. Gerald L.

Eller requesting that the Federal Highway Administration find an

additional number of your company's breakaway fiberglass

luminaire supports acceptable for use on the National Highway

System (NHS). On June 10, 1992, we wrote to you and found a

range of poles acceptable based upon pendulum testing. The

breakaway performance of these poles is achieved by weakening

various layers of the fiberglass mats near the groundline as well

as adding a bondbreaker between the layers during fabrication of

the pole. The pole is also strengthened above and below the

impact zone with additional glass reinforcement. Your current

request is to add new poles to the catalog of poles we found

acceptable in 1992. All of the new poles on your list are within

the range of poles we have already found acceptable. Details of

the pole construction may be found in the enclosed drawing and

specifications.

The following additional poles are acceptable for use on the NHS,

if requested by a State.
2 

All conditions in our June 10, 1992, letter remain in effect. 

Sincerely yours, 

2 Enclosure 

L. Poston, Chief 

Division 

Geometric and Roadside Design Acceptance Letter LS-26A 
Features of the breakawav device

Perfect sheaf of the pole upon impact was achieved through introducing the following

modifications to the conventional pole design.

1.

2.

3.

Cutting each glass laminate in the vicinity of the groundline. However

not all glass layers are cut at the same section. Cuts are staggered

approximately 4 inches apart.

Placing a layer of polyethylene foil (approx. 40” wide x 17” long) between

the glass layers in me vicinity of the impact zone. The foil has holes cut

in approximately 50% of its area to allow the passage of the resin during

spinning of the pole. The objective of me polyethylene foil is to

delaminate the pole in the impact zone, thus decreasing its shearing and

flexural resistances considerably in that zone.

Providing additional glass reinforcement above and below the impact

zone. This aids in confining the impact effect to the weakened zone and

prevents failure from spreading to other regions of the pole.
I 

34’04. 

I 

~44amm m~-u 1 

I / SCIUTHWEST RESEARCH 

L 

i CAT. No. D-wB39+-5o-S10 

SPCCS WIND VR. Bo Q ~3 

rgT LENGTH 39’4 I Un. VWHT YD LM 

c*Bca. DEPTH Y-v LUH. EPA e SQft 

T;P DIA. 5U STATTC WFI . 6@ 

__- - _ __ I___ , 

- ._. .._.-.. . 

POLE DMSION 

FFI. 7W 

DRAVN DATE +0731 1 

Figure 2. Manufacturer’s Drawing of Test Article 
U.S. Dqxlnmenr 

at TransportFederal Highway 

Administration 

400 Seventh St., S.W. 

Washington, D.C. 20590 

Refer to: HNG-14 

April 18, 1997 

Fouad H. Fouad, Ph.D., P.E. 

Professor of Civil Engineering 

Sherman Utility Structures, Inc 

P.O. Box 1926 

Birmingham, Alabama 35201 

Dear Mr. Fouad: 

This is in response to your letter of February 10 to Mr. Gerald L. Eller requesting that the 

Federal Highway Administration find an additional number of your company’s breakaway 

fiberglass luminaire supports acceptable for use on the National Highway System (NHS). On 

June 10, 1992, we wrote to you indicating the acceptability of a range of poles based upon 

pendulum testing. Subsequently, on February 15, 1996, we indicated the acceptability of 

several more specific pole sizes and configurations that fell within the range of the poles found 

acceptable earlier. The breakaway performance of these poles is achieved by weakening 

various layers of the fiberglass mats near the ground line as well as adding a bondbreaker 

between the layers during fabrication of the pole. The pole is also strengthened above and 

below the impact zone with additional glass reinforcement. Your current request is to add new 

poles to the catalog of poles we found acceptable in 1992 and 1996. All of the new poles on 

your list are within the range of poles we have already found acceptable. 

Therefore, the additional poles listed in the following table are acceptable for use on the NILS, 

if requested by a State. 

Mtg. Ht 

-u-o 

14 WO (45.92) 107.2 (236) 

130 (5.12) 369 (14.53) 

* 

130 (5.12) 369 (14.53) 

148 (5.83, 384 (15.10) 

6052 (9.38) 

6052 (9.38) 

6052 (9.38) 

D-hfB44F-5MX 

13 080 (42.92, 102.7 027) 

6052 (9.38) 

6052 (9.38) 

D-MEAM-SO-D8 

D-hiB43-G-MS10 

6052 (9.38) 

6352 (9.38) 

6052 (9.38, 

D-M&13-G-M-D,0 

D-MB43&50-S12 

D-M&,3-KXLD12 

II 380 (37.33) 

11 2W (36.75) 

II 2al(36.75) 
2 

The pole that was tested in 1992 to qualify the range of poles found accq~table by our June 10, 1992, memo was: 

DMBWF-50SlO 11 300(37.00) 20 cc0 (39.3'7) 111.8 (246) 130 (5.12) 415(16.34) 5 6052 (9.38) 

Details of the pole construction are shown in the enclosed drawings of the ten poles and a 

description of the breakaway features, also enclosed. 

All conditions in our June 10, 1992, letter remain in effect. 

Sincerely yours, 

Dwight Horne, Chief 

Federal-Aid and Design Division 

6 Enclosures 

SulIplemental to Geometric and Roadside Design Acceptance Letter LS-26~1 
Features of the breakawav device

Perfect shear of the pole upon impact was achieved through introducing the following

modifications to the conventional pole design.

1. Cutting each glass laminate in the vicinity of me groundline. However

not all glass layers are put at the same section. Cuts are staggered

approximately 4 inches apart

2. Placing a layer of polyethylene foil (approx. 40” wide x 17” long) between

the glass layers in the vidnity of the impact zone. The foil has holes cut

in approximately 50% of its area to allow the passage of the resin during

spinning of the pole. me objective of me polyethylene foil is, to

delaminate me pole in the impact zone, thus decreasing its shearing and

flexural resistances considerably in that zone.

3. Providing additional glass rainfomement above and below the impact

zone. This aids in confining the impact effect to me weakened zone and

prevents failure from spreading to other regions of the pole.
c 

0 
5. 

1, a. f2 t . 

1.2. 3, 

4.5. 

UP DIA. ,g_IN _l~g.PlM 

IaLD LENGTH ?e_<Tl _LC_M. 

8Lutd 

c0l.m NO ____ 

CLLOR ___________---___ 

VUWlf _-_-GM. 

LLE CAP 

SAMPLE 
Euti 

aI3 NO ____ 

mm --______--.-_--__ 

‘OLWY ____GAL 

I SAMPLE 

1.2. 3. t tl 1.2. 3. 

IP[)LE CAP 
_L--_l LLJ 

lR!%r~ffeML 

5. 

I, 2. e t 1.2. 3. 

4.5, 

xc cnp 

- 8 ---- -0. - __I x7-9’ 

e-9 

I

i 

WLE CAP 

- s’_,y _--- _ 7 x-9. I 

1, I P-5 ’ )’ 

I SAMPLE 
--w-o1 ---- 

-’ 

I SAMPL F 

-w-w 

_-__ - +-l-l