t 3 

U.S.Departmnt 

0fTmnspOTraficn 

FederalHiihway 

Administration 

Refer to: HNG-14 

John F. Boozer, III, P.E. 

Product Development Engineer 

Shakespeare Electronics and Fiberglass Division 

Route 3, P.O. Box 733 

Newberry, South Carolina 29108 

Dear Mr. Boozer: 

Thank you for your letter of March 26 to Mr. Thomas 0. Willett in which you 

requested Federal Highway Administration (FHWA) acceptance for your company's 

anchor base fiberglass light poles as breakaway structures. The pole-base 

series in this request are designated ASW27 through ASW35 and AHW27 through 

AHW35. In support of this request you submitted reports dated March 1990, 

of tests conducted at the Federal Outdoor Impact Laboratory, and drawings of 

the two types of cast aluminum shoe bases used in the tests. Additional 

information provided on July 31 in response to dur request included chemical 

analyses of the aluminum castings and clarification of hardware details. 

Details of the tested hardware are shown in the enclosed drawings of the 

tested pole-base combinations and fully dimensioned drawings of the anchor 

bases. The tests used an instrumented 1,850-pound bogie vehicle fitted with a 

10 stage crushable nose which simulates a 1979 Volkswagen Rabbit. All test 

bases were secured with l-inch diameter bolts torqued to 400 foot-pounds. The 

bolt circle diameter was 12 inches in each case (the bases can accommodate 

ll- to 12-inch bolt circle diameters.) The luminaire mounting height was 

35 feet. Test results are summarized below. 

Test Number 89FO39 89FO41 89FO40 89FO42 

Pole Catalog Number* ASW 35-18 ASW 35-18 AHW 35-18 AHW 35-18 

Base Casting Number** 37-60-0160-10 37-60-0208-10 

Impact Speed 20.0 mph 59.9 mph 19.9 mph 60.2 mph 

Vehicle Velocity Change 6.1 fps 6.4 fps 6.1 fps 6.6 fps 

Occupant Velocity Change 6.4 fps 4.7 fps 6.3 fps 6.7 fps 

Stub Height 2.7 in. 2.7 in. 2.7 in. 2.7 in. 

Weight of Test Article 208 # 208 # 237 # 237 # 

Pole Wall Thickness*** 0.215 in. 0.215 in. 0.28 in. 0.28 in. 

*The letter "W" was added to the designation after the tests were conducted. 

It identifies a pole whose cast aluminum base has a O.lOO-inches deep by 

0.060-inches wide annular recess cut into the inside face of the stem of the 

base l-inch above the bottom surface of the base. 

**Base casting 37-60-0160-10 is used with the ASW series. Base casting 

37-60-0208-10 is used with AHW series poles 31 feet and over. For AHW series 

poles from 27 to 29 feet, the base casting used depends upon the length of 

mast arms used. 
2

***Pole wall thicknesses are the same for all poles in the 27-foot to 35-foot

mounting height range, and vary only between pole series. Some pole-base

combinations have a l/&inch thick aluminum sleeve welded to the I.D. of the

aluminum anchor base. This sleeve is used to size down a base for proper

clearance.

The above information shows that the tested pole-base combinations met the

change in velocity and stub-height requirements adopted by the FHWA. From

these results we are convinced that all the other poles, with single or double

mast arms up to 12-feet or post mountings, in the series identified in the

enclosed product tables, will also meet the breakaway requirements adopted by

the FHWA. Therefore, the poles in the identified series are acceptable for

use on the Federal-aid projects when requested by a State.

This acceptance is limited to breakaway characteristics of the bases and does

not cover the structural features of the bases nor the poles. 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 Shakespeare that the poles and

castings furnished have essentially the same chemistry, mechanical properties,

and geometry as those used in the tests, and that they will meet the FHWA

change in velocity requirements.

Since your company's anchor base light poles are proprietary items, to be used

in a Federal-aid highway project they; (a) must be supplied through

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

highway agency certifies that they are essential for synchronization with

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

(c) they are used for research or for a distincti,ve 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,

csfd /dJifzw

L. A. Staron

Chief, Federal-Aid and Design Division

Enclosures
t.4mxuxu l Pmar ?rlr 

Manufacturer: SIUlIESPeAnE Pact no8 As J5 

Rof. POlL featsc 99PO39, YYPOI L 

Corg1et.d Bya C. HOTT 

YtIGllTS I LBSJ 

HEASURED LENGTIIS 

ltounrlnq lblghta JS’ (Ml) 

Polo Holqht 8 13’2’ (*2) 

Polo CC Holghtt 14’)’ (He) 

Maat CC bLght# 33’6’ (HO) 

lfamt CG Offmetr 3’@’ (LZ) 

Lurk, CG wlght‘ 24’10’ (M4) 

Lurln CG Offmotr 0’ (Ll) 

POLE PAnAnerrnQ 

Damr DLmc S.5’ 

Tip 0Am1 4.0’ 

MCHOR BASE PAMWt~R~ 

Accram Pwl.11 near 

A-U.0 kLghr m- (H9) 

A-Wm. Wldthc 0’ (HO 

roundmt ion SC 8 12’ (02) 

Dim lound Dulta 4‘ 401) 

amt.r1m11 ALurlnru 

EUDO thlcknoom Q. 379 

Yall fhlcknomoc 0.25’ 

nHorAal1 PIBenGlAss 

figure 4. Luminaire support measurements. 
II 

1 

3 I 

. 
t 

t 

I 
RESIN

_____

SIIAKESPEARE BREAKAWAY ANCHOR BASE LIGHT POLES

CONSTR~JCTION DETAIL S

The resins used in the manufacture of Shakespeare FRP light poles are

thermosettinq polyester. Typical mechanical properties of these resins

in unfilled, unreinforced castings are:

Ultimate Flexural Strength 13,000 to 14,000 psi

Flexural Modulus 640,000 to 680,000 psi

Ultimate Tensile Strength 9,000 to 9,500 psi

Percent Elongation 1.8 to 1.9%

Water Absorption 24hrs. .ll to -20%

GLASS REINFORCEMENT

-______-_----______

The glass reinforcement used in the manufacture of Shakespeare FRP

light poles is industry standard "I?" glass in the form of continuous

roving. The typical properties of this glass as reported in "Handbook

of Fiberglass and Advanced Plastics Composites", George Lubin, ED.,

Library of Congress Catalog Card Number 7598348, are:

Specific Gravity

Virgin tensile strength at 72O F

Modulus of Elasticity at 72O F

Elastic Elongation at 72' F

Coefficient of thermal expansion

EPOXY ADHESIVE

______-_------

2.54

500,000 psi

10,500,000 psi

4.8%

in

2.8 X 10 _____

in*F

The adhesive used in the manufacture of Shakespeare light poles is

an epoxy resin cured with polyamide resin. The viscosity of this

adhesive is modified with an organic filler so that it will remain

in place until cured. Typical properties for this adhesive are:

Compressive yield per ASTM-D695 10,000 psi

Tensile ultimate per ASTM-D638 8,000 psi

Percent elongation per ASTM-D638 8%

Flexural modulus per ASTM-D790 3.1 X 10' psi

Aluminum to Aluminum Rand 4,560 psi

Shakespeare's

for Breakaway

eaqe 2

Const. Details

Anchor Base Poles

rA356-T6 ALUMINUM CASTING

c

SEE CHART Oh

PAGE 5 FOR

DIAMETERS

-El‘IBONDED WITH EPOXY

ADHESIVE (SEE PAGE I)

POLE/BASE CASTING DETAIL

------______-___________

Shakespeare anchor bases are telescopically fitted to the outside

of the fiberglass tube and are bonded with the expoy adhesive described on page 1. The ID of the base casting is larger than the

OD of the tube by l/8" to l/rlw.

aluminum.

All base castings are A356-T6

The Shakespeare part numbers for the base castings are

listed below.

PART NUMBER POLE USED ON

_-_________ _____________

37-60-0160-10 ASW

37-60-0208-10 AHW

.'

1f required, an aluminum sleeve is welded to the ID of the base to

size it down for proper clearance.
Shakespeare's ('onst. Details

for Rreakaway AnI-her- n;tsc Poles

page 3

FILAMENT ORTENTATTON AND AMOUNT

________________--_----- _---_--

Shakespeare light poles are manufactured using a filament winding

process. Two winding angles are used for all poles. These angles

are nominally 15 degrees for the majority of the fibers and 75 to 135

degrees for thr remainder. The relative proportions of these two

angles vary with pole length and srries (standard, heavy duty, etc.).

For the pole tested August, 1989 by Southwest Research Tnstitute,

these proportions arc:

75O - 85' 15O

_----__--- _-__

nsw35 11% 89%

AHW35 8.5% 91.5%

For all poles greater than 25ft.. two layers of 75 to 85 windings

are on the inside surface and extend from the butt of the pole toward the tip to the dimensions shown below. Roving spacing in

in number of rovings per inch per layer is 5.5. Each individual

resin impregnated roving has a net cross-sectional area of .0022

square inches.

Distance from tip to end of spiral

ASW 10 ft.

AHW 10 ft.

The number of layers of 15O windings is:

No. of 15' layers Total number of rovings in

cross section

ASW 6 1,752

AHW 8 2,336

Note: When sliced at 15' to its axis, each individual resin imimpregnated roving yields a net cross-sectional area Of .00228

square inches.

POLE TAPER

________--

The ID of Shakespeare poles tapers at the rate Of .140 inches/foot.

Due to the nature of fjlament winding this yields a taper rate on

the D.D. of .130 to .138 inches/foot. Many longer poles have an

essentially straight section on the butt end. This was done to

minimize inventory for our cast aluminum anchor bases. Measuring

from t'ne tip of the poie, me maxi"", l_‘¶pe= rrll.jLllJ Ib LI .L. __wl.._ L____ I___LL^ i.. 97 ft 1

Shakespeare's Const. Details

for Dreakaway Anchor Base Poles

page 4

/-

HANDHOLE

ASW and AHW 27 thru 35 foot poles have 10 yards of 12" wide 8 oz/yd

glass cloth at the handhole area as shown above. 5 yards are applied to the bare mandrel in a spiral pattern and the other 5 yards

are applied over the spiral windings before the helical windings

^-^ _--II.._l ClLf: clyprrtru.
Shaktlspeare'n (‘onst. Details 

for Brcakawy A!r(.tmr nasr Polrs 

page 5 

DISTANCE FROM ASW SERJES AHW SERIES 

POLE TTP (ft.1 0Dlin.t 0Dtin.t 

Tip 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

13 

14 

15 

16 

17 

18 

19 

20 

21 

22 

23 

24 

25 

26 

27 

28 

29 

30 

31 

32 

33 

34 

35 

4.70 

4.83 

4.97 

5.10 

5.23 

5.36 

5.50 

5.63 

5.76 

5.90 

6.03 

6.16 

6.30 

6.43 

6.56 

6.69 

6.83 

6.96 

7.09 

7.23 

7.36 

7.49 

7.63 

7.76 

7.89 

8.02 

8.16 

8.29 

8.34 

8.35 

8.36 

8.36 

8.37 

8.38 

8.39 

ft.40 

4.90 

5.04 

5.17 

5.30 

5.43 

5.56 

5.69 

5.82 

5.95 

6.08 

6.21 

6.34 

6.47 

6.60 

6.73 

6.R6 

6.99 

7.12 

7.25 

7.38 

7.51 

7.64 

7.77 

7.90 

e.n3 

8.16 

8.29 

8.42 

a.47 

8.48 

8.49 

ft.49 

8.50 

8.51 

8.52 

8.53 

JB/hf 

INSIDE AND OIJTSIDE DIAMETERS OF ANCtiOR 

. RASF POLES OFF 35 FT MANDREI, 

(MANDREL NUMBER T-5147) 

ID (in) 

4.13 

4.21 

4.35 

4.49 

4.63 

4.77 

4.91 

5.05 

5.19 

5.33 

5.47 

5.61 

5.75 

5.90 

6.04 

6.18 

6.32 

6.46 

6.60 

6.74 

6.88 

7.02 

7.16 

7.30 

7.44 

7.58 

7.72 

7.86 

7.91 

7.92 

7.93 

7.93 

7.94 

7.95 

7.96 

7.97 

37-60-0160-10 

c ease casting 

37-60-0160-10 

rlttl 118” s1ee 

welded to 1.0. 

Of casting 
__.___ ___ 

27 Zh’h” 149 4.9 8.4 IH 75 -2.2 ‘1.2 

_..-. 

28 27’6” ILh 4.7 8.4 18 -75 3.2 1.1. 

28 17’6” I54 4.9 H.5 IR 75 1.2 3.2 

~_..__ -. - 

29_ 28’h” I?! 4.7 0.4 !!_..__-_75___22 .-7.’ 

29 28’6” 159 4.9 8.5 I8 75 3.2 3.2 

__. -. 

30 29’6” 134 4.7 8.4 18 75 3.2 3.2 

30 29’6” 164 4.9 a.5 -la 75 3.2 3.2 

- 

31 30’6” I’M 4.7 a.4 Ia 75 3.2 2.9 

___ 

31 30’6” lh9 4.9 a.5 I8 75 3.2 3.2 

~..__._ .__ ~~~ .._._.- 

4.7 H.4 18 

7.2 II’/) _~_ bllw;?H-24 B 

2.9 II’?. j ASW29-24 A 

3.2 I I”( AHW2‘#-24 8 

2.6 II ‘$ ASW30-24 A 

3. 2 i-8; AHW’IO-14 8 

2. I II l$ ASW31-24 ,, 

3.2 16 kl,l-24 B 

I. 9 I I ‘lL ASW32-24 A 

3. 2 I I ‘jr AHW32-24 B 

_~-- 

1.7 II”? ASW33-24 A 

-- 

2.9 II',, AHW33-24 n 

I.1 Ilk ASW34-24 A 

2.3 

--- 

+ AHW34-24 B 

0.9 ll$ ASW35-24 A 

-_ - 

2.0 I,'<, AHW35-24 

R 

l.ICHT POLE WITH ONE MAST ARM 

L7 26’6” II6 4.7 8.3 I8 75 3.2 3.2 3.2 11’2 ASW27-14 

27 Zh’6” 147 4.9 8.4 18 75 3.2 3.2 3.2 II"2 AHW27-14 

LB 27'6" I20 4.7 a.4 18 75_ 1.2 3.2 3.2 II'2ASW28-I4 

_ 

Base casting 

37-60-0160-10 

Base Casting 

37-60-0208-10 

Base casting 

37-60-0160-10 

ritn l/8" sleeve 

welded to I.D. 

of casting 

A Base casting 

37-60-0160-10 

B Ease casting 

~7-60-0208-10 

c Base casttng 

37-60-0160-10 

*1ttl 118" sleeve 

welded to I.D. 

of casting 

See IEST DATA 6 ACCESSOAIES Sexho,, 

lor krl Arm md Itlachmanl turdwms PM numbs,, 

M,S, ARM UllERUL-MUMINUM 

c 

C 

A A 

A 

A 

A B 

R 

A 

B C 

A 

8 

A 

R 

A 

ease casting 

37-60-0160-10 

Base casttng 

~7-60-0208-10 

Base casting 

37-60-0160-10 

with l/B” sleeve 

welded to 1.0. 

of casting 

I. I 

j.4 

2. ‘1 

!. L 

2.7 

1.2 

2.4 

3.2 

1.9 

3.2 

i;4 

$ 0 

I.2 

2.7 

!?P 

2.4 

il.7 

2.2 

. 

2.0 II1 ,’ ASW27-2; 

j.-’ I IL2 121115’7-21 

I .tl 111;: I\SW&I 

I. 2 I 112 AliW~~-~~ 

I.7 IILL ASW29-LI ‘I.2 I,bz Ai,W29-21 

1.4 III;1 ?SWxp~! 

2.9 ,I$ AtlW’lO-?! 

I .n I,kZ ASW31-21 

2.4 111~ AlJW31-2, 

0.6 II~; ASW’JL-21 

i.9 ilt~ ~~w3i-jk 

D. 4 I, k, ~ASW?3_-2( 

I. 7 l,ki AHWjlW 

Or2 l,b, ASW34-2J 

I .4 I lb; AHW34-2F 

1112 ASW35-2f 

I:2 .IL~L A,JW35-Lf 

A k3as.e casting 

37-6U-0160-10 

E, Base casting 

>7-60-0208-10 

C Base casting 

>7-60.0160-10 

witn 118” sleeve 

*elded to I.D. 

Llf casting 

c 

C 

1: 

A 

i 

A 

IJ 

A 

R 

z 

A 

R 

A 

R 

A 

I, 

C 

C 

C 

; 

A 

A 

PI 

A 

R 

A 

R 

A 

R 

A 

R 

A 

B 
I.ICHI !‘!)I.E WI

’I’H ONE MAST ABM 

C 

C 

C 

A 

A A 

A 

A 

B 8 

A 

B 

A c 

B 

A 

B 

A 

Base Casting 

37-60-0160-10 

Base casting 

37-60-0208-10 

Base casting 

37-60-0160-10 

witn 118” sleeve 

welded to I.D. 

of casting 

I\ Base casting 

37-60-0160-10 

I) Base casting 

37-60-0208-10 

c ease casting 

37-60-0160-10 

rltll 118” sleeve 

welded to I.D. 

of casting 

R 

C 

C 

C 

A 

A 

A 

A 

R 

A 

B 

A 

B 

A 

R 

A 

B 

A 

6 
C 

C 

E A 

A 

A a 

A 

A 

I3 c 

A 

H 

; 

$%-I 

R 

Base casting 

37-60-0160-10 

ease casting 

37-60-0208-10 

Base castiny 

37-6U-0160-10 

with l/8” sleeve 

welded to I.D. 

of casting 

For Anchw Base O~mawons 

Se8 Calakq Sheet GI4 

8 

c 

C 

C 

A 

A 

A 

A 

R 

A 

R 

A 

R 

A 

B 

A 

B 

A Base Casting 

37-60-0160-10 

B BaSe cast1ny 

37-60-0208-10 

c Base casting 

37-60-0160-10 

with 118” sleeve 

welded to I.D. 

of casting