t 3 

GDepartment 

of Tronspwtaticn 

Federal Hiihway 

Administration 

Refer to: HNG-14 

Mr. Robert A. Sik 

Vice President, Akron Foundry Company 

2728 Wingate Avenue 

P.O. 80x 27028 

Akron, Ohio 44319-0009 

Dear Mr. Sik: 

This is in response to your July 13 letter to Mr. Artimovich requesting 

acceptance by the Federal Highway Administration (FHWA) of Feralux CS-300 and 

CS-370 cast aluminum transformer bases for use on Federal-aid highway 

projects. Tests were conducted to assess compliance of the bases with FHWA 

breakaway requirements, which cite Section 7 of the 1985 American Association 

of State Highway and Transportation Officials' (AASHTO) Standard 

Soecifications for Structural Suooorts for Hiahwav Siqns. Luminaires and 

Traffic Sisnals. The Southwest Research Institute forwarded copies of the 

five crash test reports (Project No. 06-3116-516), dated June 1990, containing 

results of the pendulum tests on various aluminum and steel poles with these 

bases. Fully dimensioned drawings and material test reports on the aluminum 

castings had been received from you on May 31. 

The tests used an instrumented 1,800-pound pendulum fitted with a 10 stage 

crushable nose which simulates the left quarter point of a 1979 Volkswagen 

Rabbit. Impact speed was 20 mph. A summary of the tested hardware is 

presented below: 

Test Number Feralux Part Number Heiaht of Base Tested Pole Tvoe 

Test-AF-1 Feralux CS-300 9 inches 8 inches Aluminum 

Test-2 Feralux CS-300 9 inches 9 inches Steel 

Test-17 Feralux CS-300 9 inches 8 inches Aluminum 

Test-13 Feralux CS-370 9 inches 10 inches Steel 

Test-15 Feralux CS-370 9 inches 10 inches Steel 

Details of the tested hardware are shown in Enclosure I. Test parameters and 

measured and extrapolated test results and are shown on Enclosure II as part 

of Test Series IV. This information shows that the tested pole-base 

combinations will meet the change in velocity and stub-height requirements 

adopted by the FHWA. 

The 16.5 fps calculated change in velocity of Test 13 exceeds FHWA 

requirements. However, as the calculated changes in velocities nearly always 

over estimate the 60 mph results, we will consider the results of Test 13 as 

meeting the new FHWA requirements. 
2

Thus, the transformer bases manufactured for Feralux, as shown on the enclosed

drawings, are acceptable for use on Federal-aid highway projects within the

range of conditions tested, if proposed by a State. This acceptance is

limited to breakaway characteristics of the bases and does not cover their

structural features. Presumably, Feralux will supply potential users with sufficient information on structural design limitations and on installation

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

require certification from Feralux that the bases furnished have essentially

the same chemistry, mechanical properties, and geometry as those used in the

tests, and that supports with those bases will meet the FHWA breakaway

requirements.

Since these breakaway support designs 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

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 was provided with previous correspondence.

Sincerely yours,

L. A. Staron

Chief, Federal-Aid and Design Division

Enclosures

Geometric and Roadside Design Acceptance Letter LS-17
Endorsement to FHWA field offices: All of the transformer bases covered by

this letter and Geometric and Roadside Design Acceptance Letters LS-18 and

LS-19 were manufactured by Akron Foundry Company. For marketing purposes

Akron Foundry has requested these three acceptance letters to cover what is

essentially two 9-inch high transformer base models that will be manufactured

by Akron Foundry and sold by three firms: Feralux, Pole Lite, and Akron

Foundry. One model has top and bottom bolt circle ranges of 11.5 inches to

12.5 inches. It will carry a marking of CS-300 for Feralux, F-1300 for Pole

Lite, and TB-AF6-9" for Akron. The other has top and bottom bolt circle

ranges of 14.5 inches to 15.25 inches. It will carry a marking of CS-370 for

Feralux, F-1302 for Pole Lite, and TB-AF5-9" for Akron. A separate series of

tests was run to cover the Feralux model designations, while another series

was run to cover the combined Pole Lite and Akron designations. It is our

understanding that in production the Feralux bases will only be marked with

Feralux's base numbers. On the other hand, bases to be marketed by either Pole

Lite or Akron will be manufactured showing both suppliers' model numbers and

before being shipped, one model number will be removed so that only the

nominal supplier's model number will remain.
s: 

i 

I II / 

J 
AKRON FOUHORI TEST AF-1 * ALUMlNULl POLE .26WALL/.25 SLEEVE/TWIN ARMS -. 

32’ -10 l/2’ 

POLE WGT. 227 L6S. 

ARY WGT. 49 CBS. 

ARY WGT. 49 LBS. 

60 LB.LUYINAIAE (2) 100 LES. 

413 LBS.GROSS 

6.00 OIA.ACUYIWUY POLE/.26 WALL/.26 1K.I.O.r 12’LONG SLEEVE AT BASE 

MOUWTEO ON 366 16 CAST ALUYIWUY ANCHOR BASE 1’BOLTS ON 12.00 0IA.B.C 

/- 

FERALUX CS-800 T-BASE (REF.TB-2 DOTTOY) 

YOUllt l A8E ON DROUWD l .C./i2.00 DIA.U6lWG 1’ANCHORAGE 

1066 AAIHTO REOUIREYEWT8 / 1600 LB.PEWOULUY TEqT 

AlMOM FOUWORV TEOTAF-1 ON FEIALUX CS-300 T-•AOE 

PROJECTOO-8110-61. 

Figure 3. Assembly Drawing, Test AF-1 
TWIN ARMS 1 

POLE WGT. 403 LBS. 

ARY WGT. 137 LBS. 

ARY WGT. 137 LBS. 

60 LB.LUYINAIRE (2) 100 LGS. b- 

¶! 

777 LGS. GROSS ii 

ii 

I 

u 

I 

F 

5 

a 

a 

9.00 DIA. STEEL POLE / 11 GAUGE (.llS6 WALL) 

YOUWT POLE TO BASE / 1’BOLTS ON 12.00 DIA. B.C. 49’-6’ 

FERALUX CS-800 T-BASE ( REF.TB-2 BOTTOM ) 

F YOUIT BASE OI GROUND B.C. / 12.00 DIA.UIING 1’ANCHORAGE 

0’ 

1985 AASHTO REOUIREYEYTS / 1800 LB.PENDULUY TEST 

AKRON FOUllORV TKIT 2 ON FERALUX CS-SO0 T-BASE 

FlOJtCf OS-3llS-610 

Figure 3. Assembly Drawing, Akron Foundry Test 2 
--m - 

AKRON FOUNDRY TEST 16 STEEL POLE 1 1 8 

I lS’- 1 112. 

I- 

. 7-- TJ, 

POLE WOT. 066 LBS. 

AAY WOT. 110 LBS. 

ARY WQT. 110 LOS. 

60 LB. LUYIWAIRE (2) 100 LII. 

966 LBS. GROSS 

10.00 DIA. STEEL POLE X 2.21 DIA.TOP/? QAUQE 

MOUNT POLE TO BASE / 1 l/4 AHCHORAQE OW 16.00 0IA.B.C. 

/ 

FERALUX CS-270 T-BASE (REF.TQ-1 BOTTOM) 

MOUNT BASE ON OROUND B.C.1 16.00 DIA.USIWQ 1 l/4 ANCHORAQE 

I 

le.6 AAIHTO REOUIREYEWt@ I 1.00 LI.PEWDULUY TOIt 

AKIOIlCOU~BlttE@tl~ OWFERALUX C8-670t-OASE 

FROJECt OI-819@-616 

Figue 3. Assembly Drawing, Akron Foundry Test 13 
AKHOM FOUNDlY MEET I6 

r 

ALUMIWUY POLE .I6 WALL / 

- 

--__ _ 

3 

POLE WQT. 406 LOS. 

AM wa7. 42 Las. 

AIM war. 4s LBS. 

SO LO. LUYIIAIRE (2) 100 LII. 

601 LIS. QROSO 

10.00 DIA. ALUYlllUY POLE / .26 WALL 

YOUllTED ON 266 76 GAIT ALUMlWUY AWCHOI BASE l AF-1216-to-2 

1 t/4 BOLfl) ON 16.00 DIA. B.C. 

FERALUXCS-67OT-BASE (REF.TlB-16OlTOY) 

YOUWT l ME 01 16.00 DIA. ~.C.UOMQ 1 l/4 ANCHORAQE 

I’ 

I 

1066 AA6HTOREOUIREYENTS / 1600 LB.PEWDULUm T6Sf 

AK~~~~~OU*BIIVTE~T 16OIlElALUX CI-~TOT-~A~E 

PROJECT 06-6110-616 

Fig-we 3. Assembly Drawing, Akron Foundry Test 15 
AKRON FOUNDRY TEST 17 ALUmlwUU POLE .26 WALL / TWIN AnYI 

_. 

I 

t 

POLE WOT. 266 LB8. 

AIM WQT. 46 LBI. 

AIM WQf. 46 L66. 

60 LB. LUYIWAIRE (2) 100 LB,. 

!i 

442 LOS. aROSS 4 

ANCHOR BASE 

-FERALOX CI)-SO0 I-•AIE (REF.TB-2 l OTTOYI 

YOUlT DAM 01 12.00 DIA. OROUNI B l .C.U#INQ 1’AICHOKAOE I 

I 

1866 AAWTO IEOUIIEYENT8 / 1.00 LB.PEWDULUY TE8T 

AK1101FOUN~lVTtlOtltOIFElALYXC~-800T-~A6~ 

PROJECT 00-8116-616 

I 

Figme 3. Assembly Drawing, Akron Foundry Test 17 
,..*,*.~.*...**~.~..~*.~..*......”~,~.*~..........~..*...”.*.....**.~..~~,*.~**“~.~..*..~*.....**.*~~~.....**.*...*....~*........~~..*........~..*...*.....~...*~.~~.**..*.~ 

: Base : ease 

Test Test Base : rest Calf ‘d Stub Pole : Pole NOlalnal Nast : Bottom 0ot tom Bottom Bottom : TOP TPP TOP TOP 

Series Number Number ! Delta V Delta V Height Weight : Type L”ml”alre Arm : Bolt Bolt lasher Washer : Bolt Bolt Washer Washer 

! a 2Onph l 60mph (In.) W/arm h : Nount ing Length : Circle Diameter Outside Thick- ! Circle Dlaneter Outside Thick- 

! (fps) (fps) Dummy ! Height (rt) :DIametar (In.) Diameter ness :Dlameter (In.1 Dlameter ness 

(pounds) : (feet) ++ : (in.) l (l”.) (in.) ! (In.1 (in.) (in.) 

..**.~~..***.......*....~.~~.~***~~:*........*.~..~...~*...”~.......*.~**.*..~.~..*.,~...*.~..~*..~.~~.*.‘~....*..*~*.~~****.....~~~*..~...~..~~.....*.~**.*..**.~*~.......* 

IV AF-1 

IV TEST-1 

IV TEST-2 

xv TEST-10 

IV TEST-11 

IV TEST-12 

IV TEST-13 

IV TEST-14 

IV TEST-15 

IV TEST-16 

FEAALUX CS-300 3.4 6.4 

TB-AF-6-9 

POLE LITE F-1300 : 

FERALUX-CS-300 : 

TB-AF-6-9 : 

POLE LITE F-1300 : 

TB-AF-6-9 : 

POLE LITE F-1300 : 

TB3-AF-1517-17 1.Y.r: 

FERALUX CS-370 : 

TB-AF-5-9 ! 

POLE LITE F-1302 : 

FEAALUX CS-370 

TB-AF-5-9 : 

POLE LITE F-1302 : 

IV TEST-17 FERALUX CS-300 : 4.5 6.9 2.0’. 442 :ALUYINUM 

4.7 6.0 

5.3 11.1 

5.0 11.0 

4.9 7.0 

7.9 17.1 

6.6 16.5 

7.6 1W 

6.9 

5.8 

10.5 

10.1 

2.0 413 ‘ALUMINUN 

2.0 413 !ALUMINUM 

2.0 777 : STEEL 

2.0 777 : STEEL 

: 

2.0 442 :ALUMINUM 

: 

2.0 955 ! STEEL 

2.0 955 : STEEL 

2.0 955 : STEEL 

: 

2.0 591 :ALUMINUN 

2.0. 591 !ALUMINUN 

36.83 13.65 : 12 1 

36.03 13.65 ! 12 1 

49.50 14.50 : 12 

13.65 ! 12 

1 

49.50 1 

41.00 13.65 : 12 1 

55.42 15.13 : 15 

15.13 ! 15 

15.13 : 15 

! 

1.25 

54.75 

54.75 

50.08 

50.08 

41.08 

1.25 

13.65 : 15 

13.6; ! 15 

13.65 : 12 

1.25 

1.25 

1.25 

1 

2 3/4 l/2 

2 3/4 l/2 

2 3/4 l/2 

2 3/4 l/2 

2 3/4 l/2 

2 3/4 112 

2 3/4 l/2 

2 3/4 l/2 

2 3/4 l/2 

2 3/4 l/2 

2 3/4 l/2 

: 12 

12 

: 12 

: 12 

I 12 

15 

! 15 

15 

: 

15 

: 15 

! 

12 

1 2 J/4 

1 2 3/4 

1 2 3/4 

1 2 3/4 

1 2 3/4 

1.25 2 3/4 

1.25 2 3/4 

1.25 2 3/L 

1.25 2 3/4 

1.25 2 3/4 

1 2 3/4 

l/2 

l/2 

l/2 

l/2 

l/2 

l/2 

l/2 

l/2 

l/2 

l/2 

l/2 

l I.W. signifies Internal Weld . Anchor bolt nuts should not be torqued over 150 foot - pounds. 

++ All tests run with twin mast ar.s. w* A small shard of alunlnun remained between 2 and 3 inches above the base Plate.