LCM12

Version:
Issue Date:
Review By Date:
Owned By:
Authorised By:

1.1
August 2006
June 2008
Engineering Manager D & P
Executive Manager D & P

LINE CONSTRUCTION MANUAL LCM12

STOBIE POLE MANUFACTURE

REVISION TABLE
Version No

Date of Revision

1.0

June 2006

1.1

August 2006

Details of Amendment
Initial Release
Clause No. 12.5.8 Insertion of Bolted End Plate Splice requirements
Addition of Attachment 2
Refer EDC-L1007/0806

The above table lists in summary the amendments which have been made with most recent issues of this standard.
The table is updated with each re-issue. The latest amendments within the documents are marked with a change
indicator (|) in the outer margin.

CONTACT
This standard is the responsibility of the
Development and Projects Division, ElectraNet.
Please contact the indicated owner of the standard
with any inquiries.

ElectraNet
52-55 East Terrace, Adelaide, South Australia 5000
PO Box 7096, Hutt Street Post Office,
Adelaide, South Australia 5000
Ph (08) 8404 7966, Fx (08) 8404 7104

LI M I T AT I O N O F L I A B I LI T Y A N D
D I S C LA I M E R O F W A R R AN TY
ElectraNet makes no representation or warranty as
to the accuracy, reliability, completeness or
suitability for particular purposes of the information
in this document. ElectraNet and its employees,
agents and consultants shall have no liability
(including liability to any person by reason of
negligence or negligent misstatement) for any
statements, opinions, information or matter
(expressed or implied) arising out of, contained in or
derived from or for any omissions from the
information in this document, except in so far as
liability under any statute cannot be excluded.

2006 ElectraNet Pty Limited trading as ElectraNet. No part of this document may be reproduced
or copied in any form or by any means (graphic, electronic, mechanical, including photocopying,
recording, taping or information retrieval systems) without the prior written permission of ElectraNet.

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TABLE OF CONTENTS
CONTACT ............................................................................................................................................................1
12.1

SCOPE ....................................................................................................................................................3

12.2

POLE DESCRIPTION ..........................................................................................................................3

12.3

POLE DESIGNATION AND IDENTIFICATION .............................................................................3

12.3.1
12.3.2

POLE DESIGNATION ...........................................................................................................................3

POLE IDENTIFICATION ........................................................................................................................3

12.4

POLE MANUFACTURE ......................................................................................................................3

12.5

STEELWORK AND POLE ASSEMBLY............................................................................................4

12.5.1
12.5.2
12.5.3
12.5.4
12.5.5
12.5.6
12.5.7
12.5.8
12.6

MATERIALS ........................................................................................................................................4
STEEL FABRICATION ..........................................................................................................................4
FABRICATION - STEEL JOIST BENDING PROCEDURE ...........................................................................4
STEEL JOIST ASSEMBLY .....................................................................................................................5
PLACEMENT OF BOLTS .......................................................................................................................5
INSTALLATION OF CORED HOLES .......................................................................................................5
INSTALLATION OF STEP BOLT POCKETS .............................................................................................5
BOLTED END PLATE SPLICE ...............................................................................................................5
CONCRETE WORK .............................................................................................................................5

12.6.1
12.6.2
12.6.3
12.7

STRENGTH & MATERIAL SPECIFICATION ...........................................................................................5

CONCRETE PLACEMENT .....................................................................................................................6
CONCRETE CURING ............................................................................................................................6
SURFACE TREATMENT ....................................................................................................................7

12.7.1
12.7.2
12.8

GENERAL ...........................................................................................................................................7
HOT DIP GALVANISING ......................................................................................................................7
QUALITY CONTROL ..........................................................................................................................7

12.8.1
12.8.2
12.8.3
12.8.4
12.8.5
12.9

GENERAL ...........................................................................................................................................7
STEEL MATERIAL CERTIFICATES .......................................................................................................7
CONCRETE SUPPLY AND TESTS ..........................................................................................................7
POLE TESTS........................................................................................................................................8
WELDING ...........................................................................................................................................8
POLE HANDLING ................................................................................................................................8

12.9.1
POLE LIFTING.....................................................................................................................................8
12.9.2
POLE STORAGE ..................................................................................................................................9
ATTACHMENT 1 STOBIE POLE GENERAL ARRANGEMENT DRAWING ..............................................................10
ATTACHMENT 2. GENERAL GUIDELINES FOR FABRICATION & FITMENT OF BOLTED END PLATE SPLICES. .......11

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12.1 SCOPE
This section is applicable to the manufacture of Stobie poles for ElectraNet.

12.2 POLE DESCRIPTION

Stobie poles are defined as comprising a pair of preformed Universal Beam (UB), Universal Column
(UC) or Welded Column (WC) steel sections, orientated side-by-side at specified web-centers which
are connected by bolts, and the cavity between the steel sections filled with concrete.

12.3 POLE DESIGNATION AND IDENTIFICATION

12.3.1
a.

b.

Pole Designation

Standard Pole Type 724.200x46.535

where
24
= overall length of pole (metres)
200x46

= steel section depth (mm) x mass unit length (kg/m)

535

= pole steel centreline separation at bend (mm)

Dual Section Pole Type 724.350x197/310x118.700

where
24
= overall length of pole (metres)
350x197/310x118 = bottom & top steel section depths (mm) x mass unit length
(kg/m)
700

12.3.2

= pole steel centreline separation at bend (mm)

Pole Identification

Poles shall be tagged with a durable metal tag fastened by a pole bolt at an approximate height of 2
metres above top of footing.
Pole tags shall be marked thus:
1st Line:
Year of Manufacture/Batch Number
2nd Line:
Pole Reference Number
Pole manufacturer shall provide ElectraNet details of batch number coding for approval.
Pole reference number shall be determined by pole manufacturer as per the following example. Any
queries regarding Reference Number shall be referred to ElectraNet Line Engineering branch.
Eg.

Pole Drawing Title:

Pole Drawing Number:
Pole reference number:

Stobie Pole Type 724.200x46.535

T724-0000-000043
724-0043

12.4 POLE MANUFACTURE

Poles shall be manufactured in accordance with ElectraNet General Arrangement drawing T7000000-000003, details specified on relevant manufacturing drawings and approved pole modification
drawings.
Steelwork shall comply with AS4100, welding to AS1554.1 and concrete to AS3600.

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Ground-Line position and centre-of-gravity shall be marked by placing a horizontal trowel line in the
concrete as detailed in GA drawing T700-0000-000003.

12.5 STEELWORK AND POLE ASSEMBLY

12.5.1

Materials

Poles shall be manufactured from material to:

Steel sections

AS3679

Grade 300 MPa

Steel plate

AS3678

Grade 250 or 300 MPa

Concrete

AS3600

Grade 25 MPa minimum

Bolts

AS1111

Grade 4.6/S

Welding consumables

AS1553.1

Steel sections used for poles shall be UB, UC or WC sections. Steel lengths +100/-0 mm. Straightness
of steel sections = length/1000 or 3mm whichever is greater.

12.5.2

Steel Fabrication

Steel joist sections shall be straightened as required, holes formed through the joist web and a bend
installed in accordance with the procedures specified below.
All welds shall be SP (special purpose) category.
If required, longitudinal splices of steel joists shall be formed by full-strength, complete-penetration
butt welds to produce poles of appropriate lengths. Weld procedures for installation of complete
penetration butt welds shall be submitted for approval. Weld procedures shall specify the use of low
hydrogen consumables to form butt welds and steel pre-heating criteria. Pre-heating shall be
conducted if ambient temperature is less than 10C.
Holes shall be formed in accordance with AS4100. Diameter of bolt holes shall be in accordance with
the Table 5.2 below. Holes shall be placed within +/- 2 mm from the positions specified on pole
manufacturing drawings.

Pole Bolt Diameter

16 mm
20 mm
24 mm
30 mm

Formed Hole Diameter

18.5 mm
22.5 mm
27.0 mm
35.0 mm

Table 5.2: Formed Hole Diameter Through Web of Steel Joists

12.5.3

Fabrication - Steel Joist Bending Procedure

Steel joists may be bent by a cold-bending or hot-bending process as specified below.

Under no circumstances shall hot-bending be applied to galvanised steel sections as zinc
embrittlement may cause cracking.
Cold-bending may be used for bending of all steel sections up to and including 250UC sections and
those poles to be bent to sets less than 1:6. Bending shall be achieved by application of a slow-even
load.
Hot bending shall be used to bend sections greater than 250UC and on those sections to be bent at
sets that exceed 1:6. The steel section shall be heated to an even temperature and maintained at

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550-600C. The heated region shall extend beyond the area affected by the bend equal to half the
depth of the steel section (higher temperatures can cause excessive deformation). A slow even load
shall be applied to bend the section. The radius of the bend shall not be less than the depth of the
section. The sections shall be allowed to cool in air upon completion of bending.
WC sections: pole bend shall be fabricated by cutting a wedge of steel of required dimensions to
form the angle of the specified bend and re-joining the sections by a full-penetration butt weld as
specified elsewhere.

12.5.4

Steel Joist Assembly

Steel joists shall be assembled as shown on General Arrangement drawing with the tops level and any
inequality in length located at the toe. Substation yard poles used in portal frames may require
trimming of pole toes to match pole lengths.
Tolerance of steel joist centreline separation shall not exceed +/-2 mm at the top and +/-5 mm at the
bend from specified dimensions.

12.5.5

Placement of Bolts

Bolts shall be placed with heads on alternate sides of the pole and loosely tensioned before concrete is
poured.
Upon completion of the initial curing period, bolts shall be tightened to 110 Nm torque to take up
shrinkage of concrete.

12.5.6

Installation of Cored Holes

Cored holes in the concrete shall be formed on the pole centreline at locations specified on pole
manufacturing drawings by means of removable plugs orientated perpendicular to the surface of the
concrete.
Cored holes in the concrete shall be placed at a tolerance of +/- 4 mm from the positions specified on
pole manufacturing drawings. The perpendicular orientation of each cored hole centreline with
respect to the concrete surface shall not exceed 2mm.

12.5.7

Installation of Step Bolt Pockets

Step Bolt Pockets shall be formed in the concrete on all poles as per details in General Arrangement
drawing.

12.5.8

Bolted End Plate Splice

The fabricator shall provide proposed fabrication procedures for ElectraNet approval for manufacture
of bolted end plate splices if specified for fitment to a stobie pole.
Fabrication procedures and tolerances shall comply with the designers specification and the general
guidelines given in Attachment 2.

12.6 CONCRETE WORK

12.6.1

Strength & Material Specification

Concrete work shall satisfy the requirements of AS3600 and the following:

Poles released from storage after completion of Regular Curing period - concrete
characteristic compressive strength of 25 MPa at 28 days;

Poles released from storage at completion of Shortened Curing period - concrete

characteristic compressive strength of 15 MPa at 7 days (eg poles manufactured for
accelerated construction program or emergency restoration);

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Concrete slump 100 mm +/- 20 mm;

Maximum water/cement ratio: 0.6;

Maximum aggregate size 20 mm;

Admixtures used subject to approval.

12.6.2

Concrete Placement

Concrete shall not be placed when the ambient temperature is expected to exceed 30C unless
measures are taken to reduce concrete temperature and protect freshly placed concrete from direct
sunlight and drying winds.
Water shall not be added to the concrete mix after initial combination of materials, that is during
transit or placement of concrete unless strictly supervised so as to ensure the nominal water/cement
ratio is not exceeded. Alternatively, an increased slump may be achieved by application of an
approved plasticiser used in accordance with the manufacturer's specifications.
Concrete may be placed in its final position up to 90 minutes from the time of initial combination of
materials. In no instance shall concrete be used in which initial set has occurred.
Concrete shall be compacted with needle immersion vibrators or other approved vibration method.
Concrete shall be screeded so that its surface is level with the pole steel sections. Tolerance of the
concrete surface relative to the face of steel sections (after shrinkage of concrete): 5 mm.

12.6.3

Concrete Curing

Curing of concrete shall be carried out to avoid excessive shrinkage of the concrete so as not to
disrupt the bond with the steel joists and to ensure that concrete reaches its design characteristic
strength.
Curing comprises two stages: an initial curing stage and a final curing stage. Upon completion of the
initial curing stage poles may be lifted and stacked for commencement of the final curing stage.
Initial curing
Initial curing of pole concrete shall comprise an approved curing method as follows: Poles manufactured from steel sections less than 300mm deep shall be air-cured for a
minimum period of one (1) day after placement of concrete;

Poles manufactured from steel sections equal or greater than 300mm deep shall be cured for a
minimum period of two days (2) after placement of concrete.
Final curing

Final curing of pole concrete shall comprise an approved curing method for the greater period of
either the number of days given below or until a minimum characteristic concrete strength of 15MPa
has been achieved:

Regular curing period - air-curing in the open for a minimum period of 14 days

Shortened curing period application of approved curing treatment specified herein for
minimum period of 5 days.
Cold weather conditions

Should the minimum daily ambient temperature fall below 10 for more than half the specified curing
period the final curing period shall be extended. The period shall be determined to ensure the nominal
concrete strength achieves the minimum specified characteristic strength prior to release for transport
& construction.

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Hot weather conditions

Should maximum ambient temperature exceed 30C and relative humidity fall below 30% at any time
for the duration of curing period:

Protect exposed concrete surfaces from excessive drying by shading from direct sunlight and
wind or application of an approved curing compound for initial curing period;

Treat concrete surfaces with an approved curing treatment whilst in storage for final curing
period.
Approved curing treatments

Treat concrete surfaces with a curing compound to AS3799;

Seal concrete surfaces with an impermeable membrane;

Covering concrete surfaces with hessian bags and continually wetted.

12.7 SURFACE TREATMENT

12.7.1

General

Surface treatment of poles shall be specified on a project basis.

Approved surface treatment shall be black steel unless otherwise specified.

12.7.2

Hot Dip Galvanising

Poles specified to be galvanised shall be treated as follows:

Steel sections shall be hot-dipped galvanised to AS/NZS4680; bolts & nuts shall be hotdipped galvanised to AS1214;

Pole steelwork shall be galvanised after installation of welded conductor take-off plates and
crossarm attachment plates;

Damage of surface treatment caused by fabrication processes shall be wire brushed and
coated with two coats of zinc rich paint to a total thickness of 75 microns.

It is not necessary to galvanise the portion of steel that will be placed within the footing in those poles
incorporating WC sections.

12.8 QUALITY CONTROL

12.8.1

General

Material certificates, test records and other relevant manufacturing data shall be available upon
request for a period of 12 months from the date of pole manufacture unless otherwise specified. (It
should be noted that owners of poles might wish to have access to this information extending beyond
the 12 month period).

12.8.2

Steel Material Certificates

Material certificates relating to steel supplied for manufacture of poles shall be retained for the
specified period.

12.8.3

Concrete Supply and Tests

All concrete supplied for the contract shall be subject to production control testing in accordance with
AS3600. Sampling and testing shall be carried out by an approved laboratory. The cost for all testing
shall be included within the cost for pole manufacture.
Where hardened concrete is classed as defective and liable to rejection, the criteria for rejection shall
be as set out in AS3600.

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Should any concrete in completed work be liable to rejection, the Contractor may submit specimens
cut from the work for testing. Number, form and dimensions of the specimens, and the location from
which they are cut shall be subject to the approval of ElectraNet. The specimens shall be delivered to
a NATA laboratory to conduct strength, chloride permeability and other tests as directed by
ElectraNet.
All costs of obtaining specimens, delivery, testing and restoration of the structure shall be borne by
the Contractor on the occasion that the concrete does not meet the specification.
The concrete delivery docket shall indicate weight of cement and total volume of water (including
estimate of moisture in aggregate) used to the concrete mix.
Concrete properties shall be tested and assessed for compliance by slump tests and compression
strength tests.
Concrete shall be sampled from the truck at point of delivery supplied by each batching plant in order
to conduct slump tests and to form standard concrete cylinder test specimens for the lesser of each
pole production run or 50 cubic metres of concrete delivered. The test cylinder shall be fog-cured for
the specified concrete age and compression tested. Test results shall comply with AS1379.

12.8.4

Pole Tests

It is expected that new pole designs beyond the current range of poles in terms of pole lengths,
materials used or pole manufacturing process will be tested.
Test certificates shall be retained for the nominal design life of the pole type represented by the test.

12.8.5

Welding

Welders shall be pre qualified as follows: Each welder to prepare a test-piece and submit the
test-piece for visual inspection, load test and non-destructive testing by an independent inspector to
AS/NZS1554.1.
A qualified tradesperson shall inspect set-up of work and ensure welds are performed in accordance
with pole manufacture drawings and AS/NZS 1554.1, welding is carried out on the specified material
with suitable equipment and correct procedures are maintained.
Weld inspections by an independent inspector/qualified tradesperson shall comprise: 1.

Visual scan of 100% of welds;

2.

Visual inspection 20% of fillet welds;

3.

Visual inspection 50% of butt welds including portion of weld on each joist;

4.

Magnetic particle testing and either ultrasonic or radiographic testing as directed by the
weld inspector.
Weld imperfections shall not exceed permissible levels given in AS/NZS 1554.1 Table 6.2.

12.9 POLE HANDLING

12.9.1

Pole Lifting

Poles shall be lifted at two points spaced 9 metres equi-distant about the centre-of-gravity by means
of a load spreader.
The load spreader shall be of appropriate stiffness to prevent excessive flexure of the pole steel
sections, which may lead to excessive cracking of the concrete.
Care shall be taken to prevent deformation of the flanges of the steel joists by the pole grabs during
the lifting operation.
Poles shall not be lifted until after the initial curing period has elapsed unless continuously supported
on pallets or other approved formwork.

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12.9.2

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Pole Storage

Poles may be stored in the open and shall be stacked flat on their concrete face orientated horizontally
for the extent of their final curing period and until issue. Support blocks shall be spaced at appropriate
intervals to prevent undue damage to the concrete due to pole flexure along its length during the
period of storage.
For the duration of the final curing state, care shall be taken to protect poles from excessive drying
due to direct sunlight or winds throughout periods of hot weather. Protective measures may include
shading/wind breaks or application of an approved curing compound to the concrete surface. Poles
may be released from storage for transport to site at completion of curing period and achieving the
minimum characteristic concrete strength herein.

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Attachment 1 Stobie Pole General Arrangement Drawing

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Attachment 2. General Guidelines for Fabrication & Fitment of Bolted End

Plate Splices.
Item
Plate
material

Plate
preparation

Splice
fitment
tolerances

Specification
250 grade preferred

General
Comments
readily available
ease of plate preparation

minimum thickness 70mm

resist weld distortion

Slash surface grind tolerance +/- 2 thou

Typical roll plate tolerance

+/- 2mm

surface protective treatment applied after completion of

welding process
General Tolerances comply with AS4100
Plan dimension +/- 1.0mm
Maximum clearance between bearing surfaces +/- 1.0mm
Plate vertical axis with respect to pole centreline 1:500

Fabrication
Procedure

Critical to maintain
straightness of pole
Prior to welding, align pole segments tip-toe on bed to Fit bed on adjustable jack
achieve straightness tolerance.
screws.
Pole straightness pole tip deviation < +/- 50mm from pole Calibrate flatness prior to
centreline at splice
alignment of end plat using
Laser level.
Centreline mark at top, splice plates and pole face above
Mark on face plate bolt or
ground level
clip on for removal after pole
erection

Fasten end plates together

Welding

Maintain relative position of

plates during welding

Pre-qualification of welders and procedures

Independent verification of procedures by accredited weld
inspector & submitted for ElectraNet review/approval
HEZ (heat effected zone) of Pole joist steel cleaned to
bright steel condition
Pre-heating of plate and HEZ of pole joist section
SP category
Full penetration butt welds used for plate to pole joist
section
Even distribution of welds to control/ minimise distortion
of splice plate

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Weld
Inspection

ElectraNet

Butt welds: 100% visual & minimum 25% Ultrasonic or

radiographic by accredited weld inspector

Butt welds inspected prior to

placement of fillet reinforcing
weld

Fillet welds: 20% visual & 5% Ultrasonic or radiographic

by accredited weld inspector
Mag-particle as required by weld inspector

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