1200 New Jersey Ave., S.E. 

Washington, DC 20590

 

October 9, 2007 

In Reply Refer To: 

HSSD/LS-65 

Mr. Joseph M. Bowman 

HAPCO 

26252 Hillman Highway 

Abingdon, VA 24210 

Dear Mr. Bowman: 

This letter is a reply to your mail correspondence of September 2, 2007, requesting the Federal 

Highway Administration (FHWA) acceptance of your company's HAPCO Lighting Poles Embed 

Breakaway Joints for use on the National Highway System (NHS) under the provisions of 

National Cooperative Highway Research Program (NCHRP) Report 350 "Recommended 

Procedures for the Safety Performance Evaluation of Highway Features." Accompanying your 

letter was a report on testing of your system conducted by the Texas Transportation Institute 

(TTI) and test videos. 

Requirements 

Luminaire supports should meet the guidelines contained in the NCHRP Report 350, 

"Recommended Procedures for the Safety Performance Evaluation of Highway Features.” 

FHWA Memorandum “ACTION: Identifying Acceptable Highway Safety Features” of July 25, 

1997, provides further guidance on crash testing of luminaire supports and on use of low-speed 

pendulum tests as a surrogate for full-scale crash testing. 

Product description 

The following three 40 ft (12.19 m) HAPCO Lighting Poles were tested at the TTI outdoor 

pendulum testing facility: 

1) HAPCO Breakaway Joint 12591 is at the ground line and consists of a cast aluminum 

ring (Alloy 356-T6) placed inside the foundation tube and tapered support tube. This 

ring was welded to each mating surface using groove and fillet welds. The thickness of 

the ring varied from 3/8 inches to 13/16 inches. A drawing is enclosed for reference. The 

joint was tested using HAPCO A89961 Lighting Pole. The lighting pole including 

foundation tube is a 46 foot - 11 inches long tapered aluminum tube (Alloy 6063-T6) 

with a 10 inch diameter at ground level, 6 inch diameter at the top, and wall thickness of 

0.156 inches. The total height with light fixture is 45 feet. The weight of the pole with 

base is 211 pounds, the luminaire arm is 42.5 pounds, and the light fixture is 38 pounds, 

totaling a weight of 291.5 pounds. The pole was installed to a depth of 7 feet in crushed 

limestone. 
2

2) HAPCO Breakaway Joint 12592 is at the ground line and consists of the 10 inch diameter 

tapered tube fitting onto a 9 11/16 inch outside diameter machine rabbet joint in the 10 

inch diameter by 3/8 inch thick foundation tube. A drawing is enclosed for reference. 

The joint was tested using HAPCO B89962 Lighting Pole. The lighting pole including 

foundation tube is a 46 foot - 11 inches long tapered aluminum tube (Alloy 6063-T6) 

with a 10 inch diameter at ground level and a 6 inch diameter at the top. The total height 

with light fixture is 45 feet. The weight of the pole with base is 263 pounds, the 

luminaire arm is 42.5 pounds, and the light fixture is 38 pounds, totaling a weight of 

343.5 pounds. The pole was installed to a depth of 7 feet in crushed limestone. 

3) HAPCO Breakaway Joint 12593 is at the ground line and consists of the 1/2 inch thick 

plate welded to the bottom of the tapered support tube. The plate is also welded to the 

top of the foundation tube. Fillet welds (5/8 inch) are used to weld the plate to the 

support tube and the foundation tube. A drawing is enclosed for reference. The joint was 

tested using HAPCO B89963 Lighting Pole. The lighting pole including foundation tube 

is a 46 foot - 11 inches long tapered aluminum tube (Alloy 6063-T6) with a 10 inch 

diameter at ground level and a 6 inch diameter at the top. The total height with light 

fixture is 45 feet. The weight of the pole with base is 211 pounds, the luminaire arm is 

42.5 pounds, and the light fixture is 38 pounds, totaling a weight of 291.5 pounds. The 

pole was installed to a depth of 7 feet in crushed limestone. 

Testing 

Your company’s Lighting Poles Embed Breakaway Joints were tested at the TTI outdoor 

pendulum testing facility as a surrogate for full-scale crash testing. The pendulum bogie was 

built according to the specifications of the Federal Outdoor Impact Laboratory's (FOIL) 

pendulum, and the frontal crush of the aluminum honeycomb nose of the bogie simulated the 

crush of an actual vehicle. Tests with pendulums are acceptable for most breakaway supports, 

exceptions being base bending or yielding supports. 

Three low speed pendulum tests were conducted on your company’s Lighting Poles to test each 

varying breakaway joint design and summaries of the test results are enclosed: 

1.) The test of HAPCO Breakaway Joint 12591 yielded an occupant impact velocity of 

4.1 m/s, ridedown acceleration -0.6 g’s , and a maximum change in velocity of 4.5 m/s. 

2.) The test of HAPCO Breakaway Joint 12592 yielded an occupant impact velocity of 

2.5 m/s, ridedown acceleration -0.6 g’s , and a maximum change in velocity of 2.2 m/s. 

3.) The test of HAPCO Breakaway Joint 12593 yielded an occupant impact velocity of 

2.9 m/s, ridedown acceleration -0.7 g’s , and a maximum change in velocity of 3 m/s. 

The three breakaway joint designs as described above met the NCHRP Report 350 occupant risk 

criteria. In addition, the TTI extrapolated the high-speed performance of these three lighting 

poles installation from the low speed pendulum tests. I agree that the test articles appear to 

perform appropriately to make such high-speed extrapolations. All high speed extrapolations 

yielded lower change in velocity values than the paired low speed pendulum test. In each test the 

breakaway joint functioned as intended as the support tube fractured at joint near ground level 

and left no appreciable stub height remaining. This performance satisfies the FHWA limit of a 

maximum 4 inch (100 mm) stub height remaining after a support breaks away. 
3

In summary, we agree that HAPCO 12591, HAPCO 12592 and HAPCO 12593 breakaway joints 

as described above, meet the appropriate evaluation criteria for NCHRP 350 Test Level 3 

devices and may be used at all appropriate locations on the NHS when selected by the 

contracting authority, subject to the provisions of Title 23, Code of Federal Regulations, Section 

635.411 as they pertain to proprietary products. This acceptance is limited to round aluminum 

poles (alloy 6063-T6 heat treated after welding) with luminaire mounting heights up to 45 ft. 

with shafts of up to .156 inches wall thickness with diameters of up to 10 inches and embedment 

lengths not less than 7 feet. The condition of each lighting pole is classified as not being 

repairable due to the damage from impacts. All electrical wiring connectors must be breakaway 

for the poles that will be wired in the ground for power. 

Standard provisions 

Please note the following standard provisions that apply to the FHWA letters of acceptance: 

• This acceptance is limited to the crashworthiness characteristics of the devices and does 

not cover their structural features, nor conformity with the Manual on Uniform Traffic 

Control Devices. 

• Any changes that may adversely influence the crashworthiness of the device will 

require a new acceptance letter. 

• Should the FHWA discover that the qualification testing was flawed, that in-service 

performance reveals unacceptable safety problems, or that the device being marketed is 

significantly different from the version that was crash tested, it reserves the right to 

modify or revoke its acceptance. 

• You will be expected to supply potential users with sufficient information on design 

and installation requirements to ensure proper performance. 

• You will be expected to certify to potential users that the hardware furnished has 

essentially the same chemistry, mechanical properties, and geometry as that submitted 

for acceptance, and that they will meet the crashworthiness requirements of the FHWA 

and the NCHRP Report 350. 

• To prevent misunderstanding by others this letter of acceptance designated as number 

LS-65 shall not be reproduced except in full. This letter and the test documentation 

upon which this letter is based, is public information. All such letters and 

documentation may be reviewed at our office upon request. 

• The HAPCO devices are patented products and considered proprietary. If proprietary 

devices are specified by a highway agency for use on Federal-aid projects, except 

exempt, non-NHS projects, they: (a) must be supplied through competitive bidding with 

equally suitable unpatented items; (b) the highway agency must certify that they are 

essential for synchronization with the existing highway facilities or that no equally 

suitable alternative 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. 
4

• This acceptance letter shall not be construed as authorization or consent by the FHWA 

to use, manufacture, or sell any patented device for which the applicant is not the patent 

holder. The acceptance letter is limited to the crashworthiness characteristics of the 

candidate device, and the FHWA is neither prepared nor required to become involved 

in issues concerning patent law. Patent issues, if any, are to be resolved by the 

applicant. 

Sincerely yours, 

George E. Rice, Jr. 

Acting Director, Office of Safety Design 

Office of Safety 

Enclosures 

FHWA:HSSD:MLupes:tb:x66994:10/5/07 

File: s://directory folder/mlupes/LS65-Hapco.doc 

cc: HSSD (Reader, HSA; Chron File, HSSD; M.Lupes, HSSD 

 M.McDonough, HSSD) 
8/17/2007

APPENDIX C. DETAILS OF TEST ARTICLES

I

6" Oio.--

1 5'-6"

T

r 45'-0"

Mounting Height

I

Note: Shaft (89975) And Bracket (79583) Sholl Be Heot Treoted To -T6 Temper After Welding.

26':"'8"

Topered

46'-/1"

10" 0;0.-

; /Topered Alum. Tube

1/ .156" WollAlloy 6063-T6 Setin Ground Finish

10'-9"

Hondhole Freme Topped 3/8"-16NC

/ For Grounding

//,Reinforced Hondhole (4" x 6j With /' Cover And Sioiniess Sleel Hex. Hd.

G 1 Screws

Breokoway Joint ot Ground Line (See Detoil) /'-61

16

7'-0"

I

i:' ;, :' I I. : : I I ~ f '1

AU :jA L.,:!j

1 3/4" Oio. WireHole With

1 1/2" 1.0. Rubber Grommel

9 6;" ViewA-A

+0"

100/,,"-1/16" 0.0.

8 '5< "+0" " I 0 ". -1/16 .. Cost Alum. Ring

Alloy 356- T6

Breakaway Joint

(Hapeo No.7 2591)

Ground Line

REVISIONS

WARNING,00 NOT INSTALLLIGHTINGPOlES WITHOUTLUMINAIRES

Tm.EBreakaway Embed Pole

8~ hapcoCUSTOMER

Abingdon, Va.

11 Added /oint number

Figure Cl. HAPCO A89961 lighting pole.

Page 7 of33

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8/17/2007

r

'-' 14'-6"'-"-----

1 1

Cas' Aiu - I

I ~ ~

1

Wi'

,

'h' 5.5. ,m.ScreVls ~oie CO"': ~ ~",,/'.dI'" ~

---1-- ::L \1 ~/?"/ 5'-6"

2'-6" -. --~ ~J

Sir" '. ,- o,g.o. 1f II f

1

i

I

45'-0"

MOUnUng! Heigh!

26'-8"

Tapered

46'-1 ;"

i I Added ioint number

6" 0;0.'---

Nete: Sha!! (89977) And Bracket (79583) Shoji Be Heat Ireated To - T6 Temper

10" Dia, X .156" Wail Tube

Aium, Alioy 6063-T5 ._

~

' -" /

I

I Mad;;ne

,

RObbel

,

9 "1/

,,

15" C

,

'D!:O

,

O~O" ! Alum, Alloy 6003- T6 '

~"1dJiti;-'ft ''"

10"Oio.--

"

i\rD

/ TGDerad Alum, Tube

,155" Wall Moy 5053-T6

Satin Ground Finish

, --" '--~-~.-

10'-9"

Breakaway Joint

(i-fopco No.7 2592)

7'-0"

,'iandhoie Frame Tapped 3/8"-16NC

/ For Croundin9

! / /,Reinfareed .Hocdhoie (4" x 6") With I :/ Cover And Stainless Steel i/ex, Nd,

t;t1

0.

"

ScreVls ,'-6" BranKo-Hay

i '-6; '~:i ',-" :"...' I 3/4" Oia, W;re!Iole Witn

II: i 1/2" W ,Rubber Gramme' ::1 :1

II : '

I i I "

:'

LJ

' ri

At) ;!jA ",-"..j

I

i

!

."--

r~-~ l

"'--=-:7' 5"

VieVlA-A~

Wft.RNiNG:DC NW iNSTALLLIGHTING POLES WITHOUT LUMINAIRES

"[\CSlONS

T'TlE Breakaway embed Paie

18/07 I

hapco DATE 4/16/2007 owe, NO,

Abingdon, Va.

CHK'D 89962

Figure C2. HAPCO B89962 lighting pole.

Page 8 of33

~

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8/17/2007

1

5,-n

. Rise

1 45'-0'

6' Oio,--- MO!Jntinj Height

Note: Shaft (89976) And Bracket (79583) Sholl Be Heat Treated To -T6 Temper

26'~8"

Tapered try ~ 46'-//"

Plate 1/2' Thk. X 11 1/2" Dio. W/6" Oia. Hole Alum. Alloy 606/-T6

/0" Oio.

./Tapered Alum. Tube

./ ,/56" WallAlloy 6063-T6 Satin Ground finish

10'-9'

Breakaway Joint

(Hapeo No, 72593)

Hondhole Frome Topped 3/8'- raNC

I

/ For Grounding / ./

.

' ./'Reinforced Handhale (4" x 6,/ With ./' Caver And Stainless S/eel Hex. Hd

0 Screws

Breakaway Join/ 0/ Ground Une (See De/oil) Ground Line

7'-0"

r

I

1 3/4' Dio. Wire Hale With / 1/2' 1,0, Rubber Grommet

,. . '

i. ,~

:. 1 f, : : I I .1 f 'I

AU J UA L.,::.J

y-f. . ---r ~

...

/1 Added iaint number

R~

WARNING: DONOTINSTAlLlIGHTINGPOLES\\1THOUTLUMiNAIRES

TITlEBreakaway Embed Pole 8/071 hapeD:=:2OAT( 4/16/2007

BY JMB DWG. NO,

om

Abingdon. Va. CHK'D 89963

Figure C3. HAPCO B89963 lighting pole.

Page9 of33

t-; 1.0

0')

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~ Texa.

"", r::.=rtarJon
Table Dl. Summary of results for pendulum test 400001-HAP P6.

....

General Information

Test Agency Texas Transportation Institute

Test No. 400001-HAP P6

Date 07-09-2007

Test Article

Type ..Luminaire

Name HAPCO A89961 Lighting Pole

Installation Height (m) 12.2 m (40 ft)

Material of Key Element Cast Aluminum (Alloy 6063-T6)

Tapered 6-10-inch Diameter

with Breakaway Joint HAPCO No. 12591

Soil Type Standard Soil (Crushed Limestone)

Test Vehicle

Type Bogie

Designation Pendulum

Test Inertia Mass ..839 kg

~.~ I Impact Conditions

Speed .34.9 km/h

Angle.. , 90 deg

Occupant Risk Values

Impact Velocity

Longitudinal direction .4.1 m/s

Ridedown Accelerations

I Longitudinal direction 0.6 g's 1 Maximum change in Velocity 4.5 m/s

~ .J Predicted High-Speed Change in Velocity 2.7 m/s

0.295 s BreokoWQY Joint

(Hapco No. 12591)

8/17/2007 Page 13 of 33 ~~ ..."", ~
Table D2. Summary of results for pendulum test 400001-HAP P7.

0.296 s

8/17/2007

General Information

Test Agency Texas Transportation Institute

Test No. 400001-HAP P7

Date 07-09-2007

Test Article

Type ,...Luminarie

Name HAPCO B89962 Lighting Pole

Installation Height (m) 12.2 m (40 ft)

Material of Key Element Cast Aluminum (Alloy 6063-T6)

Tapered 6-10-inch Diameter

with Breakaway Joint HAPCO No. 12592

Soil Type Standard Soil (Crushed Limestone)

Test Vehicle

Type Bogie

Designation Pendulum

Test InertiaMass " ..839 kg

Impact Conditions

Speed ..35.1 km/h

Angle 90 deg

Occupant Risk Values

Impact Velocity

Longitudinal direction .2.5 m/s

Ridedown Accelerations

Longitudinal direction 0.6 g's

~ I Maximum change in Velocity 2.2 m/s

Predicted High-Speed Change in Velocity 1.9 m/s " ,<, ." - .,,,, .'"-''''","".p.

t <

Page 17of33 ~ 1ex'"

.._T"'~1fatlon

- In5lltille
Table D3. Summary of results for pendulum test 400001-HAP P8.

0.296 s

8/17/2007

General Information

TestAgency ..TexasTransportationInstitute

Test No. " 400001-HAP P8

Date 07-09-2007

Test Article

Type Luminaire

Name HAPCO B89963 Lighting Pole

Installation Height (m) 12.2 m (40 ft)

Material of Key Element Cast Aluminum (Alloy 6063-T6)

Tapered 6-10-inch Diameter

with Breakaway Joint HAPCO No. 12593

Soil Type Standard Soil (Crushed Limestone)

Test Vehicle

Type Bogie

Designation ""'"'''''''''''''''''''''''''''''''''''''''''''''' Pendulum

Test Inertia Mass 839 kg

Impact Conditions

Speed .34.9 km/h

Angle.. 90 deg

Occupant Risk Values

Impact Velocity

Longitudinal direction.. ...2.9 m/s

Ridedown Accelerations

Longitudinal direction ..-0.7 g's

Maximum change in Velocity 3.0 m/s

Predicted High-Speed Change in Velocity 2.1 m/s

@1/ 1/2" mo. W/6" rM 1<0.'

~

5'" =;;g; :OV:T6

~

Joint ( .. f--=>J (Hapeo Breakaway No. 72593)

Page 21 of33 ~_. ..,.~r:.=::m11ml