t

3

U.S.Department

of Transportation

Federal Highway

Administmtion Refer to: HNG-14

Mr. Robert A. Sik

Vice President, Akron Foundry Company

2728 Wingate Avenue

P.O. Box 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 your company's 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 Specifications for

Structural Suooorts for Hishwav Sians. Luminaires and Traffic Siqnals. The

Southwest Research Institute forwarded copies of the five crash test reports

(Project No. O6-3116-516), 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 Akron Foundrv Number Height of Base Pole Tvoe

Test-l TB-AF-6-9 9 inches 8 inches Aluminum

Test-10 TB-AF-6-9 9 inches 9 inches Steel

Test-11 TB-AF-6-9 9 inches 8 inches Aluminum

Test-12 TB3-AF-1517-17 I.W. 17 inches 10 inches Steel

Test-14 TB-AF-5-9 9 inches 10 inches Steel

Test-16 TB-AF-5-9 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 17.1 fps and 16.8 fps calculated changes in velocity of Tests 12 and 14,

respectively, exceed FHWA requirements. However, as the calculated changes in

velocities nearly always over estimate the 60-mph results, we will consider
the Test 14 results as meeting the new FHWA requirements. 

absence of other test evidence, we believe the calculated 

velocity for Test 12 is beyond the limit we should accept 

qualification. 

2 

However, in the 

60-mph change in 

without 

Thus, the transformer bases manufactured by your company and distributed 

under the product numbers shown above, 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, except that for base 

TB3-AF-1517-17 I.W. for which our acceptance is limited to use were the 

combined supported weight of the pole, mast arm, and luminaire does not exceed 

900 pounds. This acceptance is limited to breakaway characteristics of the 

bases and does not cover their structural features. Presumably, you will 

supply potential users with sufficient information on structural design 

limitations and on installation requirements to ensure proper performance. 

We anticipate that States will require certification from Akron Foundry that 

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 your company's 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 prior 

correspondence. 

Your letter also requested acceptance for TB-1 and TB-2 bases tested with 

heavier pole hardware. Enclosure III is a copy of our letter of acceptance 

dated May 30, 1990, sent in response to an earlier request. 

Sincerely yours, 

c/ .&& 

L. A. Staron 

Chief, Federal-Aid and Design Division 

Enclosures 

Geometric and Roadside Design Acceptance Letter LS-I9 
Endorsement to FHWA field offices: All of the transformer bases covered by

this letter and Geometric and Roadside Design Acceptance Letters LS-17 and

LS-18 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.
\- 1.76R 

l/t -13 TAP THRU FOR DROUND SCREW 

20 TAP THRU FOR DROUND SCRE 

/ f 

7- 

, 

17.44 so. 

I 

_ + -- 

I 

\ 9.76 x 11.75 DOOR 

\ 

AF 1617 - 17 I.W. 

\ 

_-- 

-MIG, 4043 WIRE 5/ 16 r\ 

fiWlTH APPROX. 6’ OF WELD ON EACH, OF THE ( 4 ) INTEPNAL CORNERS 

\ 

I 2 314 DIA. F 1 b/l6 F 3/2 TK. STEEL WASHEPS FOP 4 l/d DIA. ANCflORAGE 

4 PLS, EO, SPACED ON 15.00 DIA. THRU 17.25 DIA! BOTTOM QROUND B.C. 

. . \ 

vH2V ADDITIONAL STATlC LOADINO IS REOUIPED PN 16.00 &I. B.C. APPLICATLDNS USE Si8 JI 2 3/4 x 4 l/4 

RECTANGULAR STEEL’WASHER UNDER 2 3/4 6 1 1110 I.D. ?c l/2 TK. WASHERS FOR 1. DIA. OROUND YOUNTINQ B.C. 

\ 

2 3/4 .DIA. I 1 6/16 LO. x .1/2_JJ5. STEEL WASHERS 4 PLS. EO. SPACED ON 13.60 DIA. THRU 16.12 DIA. B.C.- 

DoOR SUPPLIED/BLANK OR I.000 IN ALUMINUM OR PLASTIC WITW OR WlfHOUT..MIW@E 

TS3 - AF 1617 - 17 I.W. 

MATERIAL MELTED AND MANUFACTURED IN THE USA. CASTINOS PRODUCED IN THE USA. 

SPECIAL CUT-OFF 17.25 DIA.QROUWD MDURT ONLY 
I 

v- I 

-- - I z . b 

DANGER ’ 

i HIGH VOLTAGE DO NOT TAMPER I I 

LKBOW FOUWDRV TEST 1 l _ ACUYIHUN POLE .2SwAL1/.26 SLEEVL/lWIM 

POLE WOT. 221 LBS. 

ABY WOT. 43 LBS. 

ARM WOT. 43 LBSso LB.LUYINAIBE (2) 100 LBS. 

413 LBS.GROSS 

32’-10 l/2‘ 

(1.00 DIA.ALUYIWUY POLE/.26 WALL/.26 TK.1.D.x 12’LOHQ SLEEVE AT BASE 

MOUNTED ON 266 TO CAST ALUYIWUY ANCHOR BASE 1’BOLTS ON 12.00 DIA.&C. 

36'-10" 

ROtI FOUKDRV lbAFO-0 T-BASE (REF.TB-2 BOTTOW 

YOUWT KASE OK GBOUK,D &C/12.00 DIA. UIlYQ 1’ANCHOKA~E 

POLE-LITE F-1$00 T-BASE (REF.TB-2 BOTTOM) 

NOUKT OK OBOUKD &C./ 12.00 DIA.USIWO 1’ AWCHORAOE 

1086 AAIHTO REOUlREWEhTE / 1.00 LB.PEKDULUY TEST 

AKRON FOUNDRY TEOT 1 ON ‘III-AF0-B T-BASE 

PROJECTOB-8110-610 

Figure 3. Assembly Drawing, Akron Foundry Test 1 
r 

POLE WGT. 403 LBS. 

ARM WGT. lS7 LBS. 

ARM WGT. 117 LBS. 

50 LB.LUYINAIRE (2) 100 LBS. c 

3 

.I 

777 LBS. GROSS ii 

ii 

x 

C 

a 

; 

3 

/- 9.00 DIA. STEEL POLE / 11 GAUGE (.1196 WALL 1 

MOUNT POLE TO BASE / 1’BOLTS ON 12.00 DIA. B.C. 40’-6’ 

AKRON FOUNDRY TB-AFO-O T-BASE (REF.TB-2 BOTTOY) 

UGDWT 8ASE ON GROUND B.C. / 12.00 DIA.USING l’BOLT8 ON 12.00 DIA.&C. 

OR 

fPOLE-LITE F-la00 T-BASE (REF.TB-2 BOTTOM) 

YOUlT BASE ON MOUND B.C. / 12.00 DIA.USlllG 1’DOLTS ON 12.00 DIA.&C. 

1986 AASNTO REQUIREMENTS / 1800 LB.PENDULUY TEST 

AKRON POUWDRV tE@T 10 ON POLE-LITE P-1800 T-BASE 

PROJECt06-8110-61. 

Figure 3. Assembly Drawing, Akron Foundry Test 10 
KBON FOUNDRV TEST 11 ALUMINUM POLE .25 WALL 1 TWIN 

POLE WGT. 256 LBS. 

ABY WGT. 43 LBS. 

ABY WGT. 43 LBB. 

- ---A%/ POLE-LITE F-1300 T-BASE (REF.TB-2 BOTTOY) 

50 LB.LUYINAIRE (2) 100 LBS. 

442 LBS. GROSS 

5.00 DIA. ALUMINUM POLE / .25 WALL 

YOUNTED ON 356 Tb CAST ALUYINUY ANCHOR BASE 

1’BOLTS ON 12.00 D1A.B.C. 

AKRON FOUNDRY TB-AF6-9 T-BASE (REF.TB-2 BOTTOY) 

MOUNT ON GROUND B.C./ 12.00 DIA.USIkG .l’ ANCHORAGE 

OR 

T 

0’ IIY YOUWT ON GROUND B.C./ 12.00 blA.USlNQ 1’ ANCHORAGE 

4, 

i 

i 

1 

I 

, 

41*-o” 

1085 AASHTO AEOUIREYENTS / 1000 LB.PENDULUY TEST 

AKRON COUIBRV TBBT 11 ON AKRON FOUNDRV TB-AF6-B T 

PROJECT OB-311B-110 

Figure 3. Assembly Drawing, Akron Foundry Test 11 

. 
RON FOUNDRV TEST 12 STEEL POLE / TWIN ABUS1. f- 

. 

I 

[ 

I 

. 

I, 

4S’-7’ 

I 

t 

POLE WOT. OS6 LBS. 

ARM W6l. 110 LBS. 

ARY WOT. 110 LB8. 

60 LB. CUYIWAIRE (2) 100 LB% k 

P 

056 LBS. DROSS 

: 

10.00 DIA. STEEL POLE X 3.21 DIA.TOP/‘I DAUDE 

YOUKT POLE TO BASE / 1 t/I ANCHOAAQE OB 16.00 0IA.B.C. 

I 

/- 

AKROW FOUllDBV TB2-AF 1617-t.7 I.W. 

YOUNT l A8E OK OROUND B.C.1 17 t/4 DIA.USlNO 1 l/4 ANCHORAQE 

4 

I 

tSB6 AASHTO REOUIREYEWf8 / tBO0 LB.PEWDULUY TEBT 

AKRON FOUWDRV TEST, 12 011 TBO-AF 1617-17 I.W. 

PBOJECT O.-B1 tB-St@ 

Figum 3. Assembly Drawing, Akron Foundry Test 12 
AfiRON FOUWUfir TEST 14 

POLE WGT. 696 LBS. 

ARY WGT. 110 LBB. 

ARY WGT. 110 LBB. 

60 LB. LUYINAIRE (2) 100 LBB. 

7 

966 LBS. GROSS 

/- 

10.00 DIA. STEEL POLE X 9.21 DIA.TOP/‘I GAUGE 

MOUNT POLE TO BABE / 1 l/4 ANCNOBAQE ON 16.00 0IA.B.C. 

J 

AKRON FOUNDRY TB-AFI-B T-BASE (BEF.lB- 1 BOTTOM) 

NOUN1 BASE ON GROUND B.C./ 16.00 DIA.UIING 1 l/4 ANCHORAGE 

OR . 

POLE - LITE F-1002 T-BASE (REF.TB-1 BOTTOY) 

MOUNT BABE ON GROUND B.C.1 16.00 DIA.U#lNG 1 l/4 ANCHORAGE 

lBB6 AABNTO AEOUIREYENTI / lBO0 LB.PENDULUY TEIT 

(LKIW FOUlOR? ‘I~t.14 ON TB-AFI-0 T-BASE 

F1011010.-8110~(110 

. 

Figure 3. Assembly Drawing, Akron Foundry Test 14 
AKRON FOUNDRY TEST10 

I 

I 

ALUNINUY POLE .26 WALL 1 

-7-- - POLE WBT. 406 LBS. 

Am WBT. 48 k.66. 

ARY WQT. 48 LBB. 

60 LB. LUYIKAIRE (2) 100 LB8. c 

601 CBS. BBOS8 : 

f 

. 

10.00 DIA. ALUYlNUY POLE / .26 WALL 

MOUKTEDOW 66616 CASTALUYINUY ANCHORBASE 4 AF-lSl6-10-2 

’ /- 11/4BOLYSO” 16.00DIA.B.C. 

AKRON FOUWDRYTB-AFS-0 l-BASE(REF.lB-1 BOYYOU) 

WOUlt BASE 01 16.00 DIA. B.C.USIWQ 1 l/4 AWCHOKADE 

OR 

I 

1006 AASHTO REOUIREYENTS / 1600 LB.PENDULUY TEST 

AKROlFOUNDlVTEBT 16 ONTB-AFS-B T-BASE 

PROJECT OS-6116-618 

Figure 3. Assembly Drawing, Akron Foundry Test 16 
.*.~,.*.~.~,.~,*,**.*..,~.~.,...*...,.,~*.*...,,.,..*~~,.*,..,.,~*~..,.~*~.~~,~,~.*..,.~.*..*.**~.*.*~~...*.~~~*..~..*.~***”..*..*.~~*.~*.....~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 

: Base : Base 

Test Test Base : Test Calc’d Stub Pole : Pole Nominal Mast ! Bottom Bottom Bottom Bottom : TOP TOP TOP TOP 

series Number Number : Delta V Delta V Height Weight : TYPe Lumlnalre Arm ! Bolt Bolt Washer Washer ! Bolt Bolt Washer Washer 

! @ ZOmph 0 60mph (in.1 W/arm 6 ! nount1ng Length : Circle Diameter Outside Thick- : Circle Diameter Outslde Thick- 

: (fps) (IPS) Dummy : Height (ft) :Oiameter (In.) Diameter “eSS :01ameter (In.) Olameter “eSS 

(pounds) ! (feet) ++ : (I”.) l (in.) (in.) : (in.) (I”.) (in.) 

*...~~*~~**.~.**.~~....**~**.~*~***~.~~.~..*.~~*..“*.~~~~..****.~*,,.~~***.~,~~~.~.,**...*.*~.*..~:~~**..*.~*~*...~*“.***.*.~~~~*.~~.~*:~..*.*.*.*..*..~‘*..~.**.*~*.***~*~‘ 

IV AF-I 

IV TEST-l 

FEAALUX CS-300 : 3.4 6.4 2.0 413 :ALUNINUM 36.83 13.65 ! 12 1 12 1 

TB-AF-6-9 

POLE LITE F-1300 : 

4.7 6.0 36.03 13.65 : 12 1 12 1 

IV TEST-2 FERALUX-CS-300 5.3 49.50 

IV TEST-10 TB-AF-6-9 5.0 

POLE LITE F-1300 : 

TB-AF-6-9 4.9 

POLE LITE F-1300 : 

11.1 

11.0 

2.0 413 !ALUNINUN 

2.0 777 : STEEL 

2.0 777 : STEEL 49.50 

14.50 : 12 1 

13.65 ! 12 1 

! 12 1 

: 12 1 

IV TEST-11 7.0 2.0 442 :ALUNINUN 41.00 13.65 : 12 1 12 1 

: 

IV TEST-12 lB3-AF-1517-17 I.W.+: 7.9 

FERALUX CS-370 : 6.6 

17.1 55.42 

IV TEST-13 16.5 

15.13 : 

l5 LJ 1’25 

15.13 : 15 1.25 

IV TEST-lb TB-AF-5-9 : 7.6 

POLE LITE F-1302 : 

16.0 

2.0 955 : STEEL 

2.0 955 : STEEL 

2.0 955 : STEEL 15.13 : 15 1.25 

15 1.25 

15 1.25 

: 15 1.25 

IV TEST-15 

IV TEST-16 

FERALUX CS-370 : 6.9 

TB-RF-5-9 : 5.6 

POLE LITE F-1302 : 

10.5 

10.1 

2.0 591 :ALUNINUM 

2.0. 591 :ALUWINUH 

54.75 

54.75 

50.08 

50.08 

41.08 

13.65 : 15 1.25 

13.65. : 15 1.25 

: 

2 3/b l/2 

2 3/b l/2 

2 3/b l/2 

2 3/b l/2 

2 3/b l/2 

2 3/b l/2 

2 3/b l/2 

2 3/b l/2 

2 3/b l/2 

2 3/b l/2 

2 314 l/2 

15 1.25 

15 1.25 

IV TEST-17 FERALUX CS-300 4.5 6.9 2.0s’ 442 :ALUNINUH 13.65 : 12 1 : 12 1 

2 3/b l/2 

2 3/b l/2 

2 3/b l/2 

2 3/b l/2 

2 3/b l/2 

2 3/b 112 

2 3/b l/2 

2 314 l/2 

2 3/b l/2 

2 3/b l/2 

2 3/b l/2 

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

+* All tests run with twin mast arms. .* A small shard OC alunlnum remained between 2 and 3 inches above the base Plate.