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CSP Pacific | Oclyte Product & Installation Manual | May 2011

Oclyte Modular Octagonal Steel Columns

Product & Installation Manual

02

Oclyte

tm

Lighting
Columns

Contents
Introduction

04

Streetlight columns

06
08
09
10
11

Standard ground planted

Standard shear or flange
Pedestrian crossing
Subdivision column 
Standard outreaches 
Alternative outreaches 

Floodlighting columns
Floodlight Columns and Cross Arms
Seesaw - lowering column
Planting options
Holding-down assemblies
Oclyte column identification 

12
13
14
15
16
17
18
19

Assembly and
installation instructions

20

Shear base assembly, installation

and maintenance

26

Optional corrosion protection

Oclyte Tuff Coat

28

03

Introduction
The Oclyte modular steel column is now a familiar
sight in most towns and cities of New Zealand and
has gained wide acceptance in Australia, the Pacific
Islands and South East Asia.
The column comprises a range of interchangeable
octagonal tapered steel elements each of which
friction-fit together to provide the desired height.

Benefits
Competitively priced
Automation of production has provided a very efficient and
low cost manufacturing process. This is reflected in the
purchase price and combined with a low installation cost
provides the client with a very competitively priced pole.
Safe design
The lightweight steel construction minimises both personal
injury and property damage when struck by vehicles. A
special frangible base which shears off on impact, is used
in areas with a high traffic density to further reduce the
possibility of serious injury.
Aesthetics
The continuous tapering octagonal shape from spigot to
base provides a visually pleasing and unobtrusive form in
street furniture.
Low maintenance and repair costs
The modular construction permits replacement costs to be
restricted to only the affected elements, eliminating the need
for total pole renewal.
Hot dip galvanizing after fabrication to AS/NZS 4680:1999
- Hot Dip Galvanized (Zinc) Coatings on Fabricated
Ferrous Articles, ensures long service life without costly
maintenance.
Typical coating weights are 500550 g/m2.
Ease of transportation, storage and assembly
With the modular elements nesting inside one another
transportation and storage costs are reduced.
Further savings are gained during assembly where the
lightweight elements can be readily mated to friction fit
without craneage or sophisticated erection equipment.
Versatile design
The wide range of interchangeable elements provides top
flexibility in column selection as is evidenced in the following
tables.
This combined with the potential to vary the steel thickness,
as dictated by the imposed loads, gives an economic design
without compromising the aesthetics.

04

Oclyte

tm

Column Applications

Lighting
Columns

Applications
Street Lighting
Undergrounding of electricity has led to an increasing demand
for an aesthetically pleasing column for street lighting in both
residential and commercial areas.
The Oclyte series provides an extremely versatile combination
of mounting heights, base types and outreach shapes to satisfy
the requirements of the most fastidious designer.
The standard columns are detailed in the following illustrations.
Floodlighting
Security requirements, outdoor displays, sportsfields and work
areas require varying degrees of llumination which in turn need a
versatile column on which to fix the appropriate lanterns.
A wide range of Oclyte columns of varying design capacities
are available to maximise the illumination needed and these are
detailed later.
Communication Columns
A number of communication systems, utilising radio and/or
microwaves, require columns of minimum deflection and heights
in excess of 20 metres.
Oclyte columns are widely used for this purpose and are
usually individually designed.
Power Transmission
Remote or difficult areas may require a modular column for ease
of installation. Oclyte has been successfully used for both low
and high tension lines.

05

Streetlight columns

06

Oclyte

tm

Lighting
Columns

Streetlight columns
Standard Dimensions

Column Assembly

The standard module is 3.6 metres in overall length with the net
length varying with the lap.

See the detailed Installation Instructions on pages 20 to 27 of

this manual.

Element
Number

Across Flats
at Base of
Element (mm)

Approx Mass (kg) After

Galvanizing Steel
2 mm
Steel

3 mm
Steel

89

12.5

155

23.6

35.2

220

36.5

54.5

282

49.0

73.0

342

61.0

90.8

400

72.8

108.2

457

83.9

124.7

511

140.9

Gear Opening Sizes

Standard sizes for gear openings are:
Elements 01/2

150 75

Elements 27

300 150

Manufacture
The columns are manufactured from mild steel with a minimum
yield of 250 MPa ranging in thickness from 210mm which, after
folding, are seam welded and then hot dip galvanized to AS/NZS
4680:1999.
Higher yield steels are also used where high loads and taper
constraints dictate.

Design
The Oclyte columns are computer designed, based on
the sail area for the particular wind speed at installation. The
sophisticated programme ensures an exact evaluation of the
pole loadings and thus an efficient design to Australian and
New Zealand Design Codes NZS 3404: 1997, AS/NZS 4600:
1996, AS/NZS 1170: 2002 and AS/NZS 4676:2000.
The elements are generally 3.6 metres in length with half
sections used where necessary to provide a full range of
mounting heights. They are enumerated from section O at the
top on an approximate taper of 21mm per metre.

Spigot Sizes
Spigot sizes are generally 34 or 42mm OD 150mm long for
street light fittings and 76mm OD 110mm for post top fittings.
It is necessary to specify size and length when ordering.

Foundations
Columns are either ground planted or flange mounted.
Ground Planted
Columns are planted to depths shown in the tables (as a guide
only) assuming good ground as per NZS 3504:1999.
It is recommended that a hole approximately 200mm diameter
oversize is excavated to allow for placement of selected granular
(GAP20 or similar) or dry concrete backfill (min. 20Mpa) around
the column.
Flange mounted
Concrete footings are designed by others to suit column
loadings as supplied by CSP Pacific.
Standard holding down bolt assemblies are available. Care
should be taken to ensure correct orientation of H.D. bolts
during footing construction and a template must be used to
ensure correct spacing of bolts for the circular type assemblies.

07

Standard ground planted

curved

elliptical

mitred
OUTREACH

OUTREACH

OUTREACH

25

10

17

SPIGOT

SPIGOT SIZED TO
SUIT LANTERN

1
MOUNTING HEIGHT

GEAR OPENING

08

150 75 CABLE ENTRY

DWG NO.

ELEMENTS
UTILISED

COLUMN HEIGHT
WITHOUT O/R (m)

PLANTING
DEPTH(m)

WEIGHT COLUMN
ONLY (kg)

OMINAL MOUNTING
HEIGHT(m)
STREETLIGHT COLUMNS - GROUND PLANTED

GROUND PLANTING
DEPTH

1.0m

5.5

P1590

1-1/2 2

3.96

1.2

40.0

5.52

5.75

5.95

6.15

5.46

5.32

5.67

5.85

7.0

P724

1-2

5.42

1.5

60.0

6.97

7.20

7.40

7.60

6.91

6.77

7.12

7.31

7.5

P912

1-2

3.62

1.5

50.0

7.67

8.41

8.0

P725

1- 1/2 3

6.52

1.8

83.0

8.08

8.31

8.51

8.71

8.02

7.88

8.23

8.41

9.52

ACTUAL TOTAL HEIGHT OF COLUMN WITH OUTREACHES

(MEASURED TO SPIGOT FROM G/L)
CURVED (Dwg No. P602)

MITRED (Dwg No. P603)

ELLIPTICAL
(Dwg P470 &
P1903)

2.0m

3.0m

4.0m

1.0m

2.0m

3.0m

4.0m

2.5m

4.0m

9.0

P911

1- 1/2 3

4.72

1.8

74.0

8.78

10.0

P713

1-3

8.12

2.0

110.0

9.68

9.91

10.11

10.31

9.62

9.48

9.83

10.01

10.5

P714

1-3

6.32

2.0

100.0

10.38

11.12

11.0

P717

1- 1/2 4

9.21

2.2

138.0

10.77

11.00

11.20

11.40

10.71

10.57

10.92

11.10

11.5

P718

1- 1/2 4

7.41

2.2

128.0

11.47

12.21

11.75

P1782

1- 1/2 4

9.72

1.7

138.0

11.28

11.51

11.71

11.91

11.22

11.08

11.43

11.61

12.0

P1345

1-4

10.23

2.4

160.0

11.79

12.02

12.22

12.42

11.73

11.59

11.94

12.12

12.5

P905

1-4

10.71

2.5

170.0

12.27

12.50

12.70

12.90

12.21

12.07

12.42

12.60

13.0

P906

1-4

8.91

2.5

160.0

12.97

13.71

13.5

P931

1- 1/2 5

11.62

2.8

205.0

13.17

13.40

13.60

13.80

13.11

12.97

13.32

13.51

14.0

P932

1- 1/2 5

9.82

2.8

195.0

13.87

14.61

Oclyte

tm

Lighting
Columns

Standard shear or flange

curved

elliptical

mitred

OUTREACH

OUTREACH

OUTREACH
25

10
17

SPIGOT

SPIGOT SIZED TO
SUIT LANTERN

1
MOUNTING HEIGHT

GEAR OPENING
3
G

75

GROUND PLANTING
DEPTH

700

150 75 CABLE ENTRY

CONCRETE FOOTING
BY OTHERS

OMINAL MOUNTING
HEIGHT(m)

DWG NO.

ELEMENTS
UTILISED

COLUMN HEIGHT
WITHOUT O/R (m)

PLANTING
DEPTH(m)

WEIGHT COLUMN
ONLY (kg)

Streetlight Columns - Shear/Flange Based

Note: Any of the three outreach types may be combined with either type of base. Standard holding down bolt assemblies or ground
stubs available for flange mounted columns.

1.0m

5.2

P2130

3.72

1.2 (FB), 1.8(SB)

40.8

5.27

5.50

5.70

5.90

5.21

5.07

5.42

5.61

7.0

P924

1- 1/2 2

5.23

1.5 (FB), 1.8(SB)

58.0

6.79

7.02

7.22

7.42

6.73

6.59

6.94

7.12

8.5

P923

1-2

7.03

1.5 (FB), 1.8(SB)

76.0

8.59

8.82

9.02

9.22

8.53

8.39

8.74

8.92

9.3

P922

1-2

5.21

1.5 (FB), 1.8(SB)

68.0

9.27

10.01
-

ACTUAL TOTAL HEIGHT OF COLUMN WITH OUTREACHES

(MEASURED TO SPIGOT FROM G/L)
CURVED (Dwg No. P602)

MITRED (Dwg No. P603)

ELLIPTICAL
(Dwg P470 &
P1903)

2.0m

3.0m

4.0m

1.0m

2.0m

3.0m

4.0m

2.5m

4.0m

9.5

P723

1- 1/3 3

7.82

1.8

95.0

9.37

9.60

9.80

10.00

9.31

9.17

9.52

9.71

10.0

P894

1- 1/2 3

8.44

1.8

103.0

9.99

10.22

10.42

10.62

9.93

9.79

10.14

10.33

10.0

P903

1- 1/3 3

6.02

1.8

85.0

10.07

10.81

10.5

P716

1- 2/3 3

9.04

1.8 to 2.4

118.0

10.59

10.82

11.02

11.22

10.53

10.39

10.74

10.93

10.7

P919

1- 1/2 3

6.62

1.8

93.0

10.67

11.41

11.3

P901

1- 2/3 3

7.22

1.8 to 2.4

108.0

11.27

12.01

12.0

P720

1-3

10.24

1.8 to 2.4

140.0

11.79

12.02

12.22

12.42

11.73

11.59

11.94

12.13

12.5

P896

1- 1/3 4

10.93

2.4

154.0

12.48

12.71

12.91

13.11

12.42

12.28

12.63

12.82

12.5

P893

1-3

8.42

2.4

129.0

12.47

13.21

13.0

P917

1- 1/2 4

11.53

2.4

164.0

13.08

13.31

13.51

13.71

13.02

12.88

13.23

13.42

13.2

P721

1- 1/3 4

9.11

2.4

143.0

13.16

13.90

13.8

P918

1- 1/2 4

9.71

2.4

153.0

13.76

14.50

15.0

P1795

1-4

13.33

3.0

197.0

14.88

15.11

15.31

15.51

14.82

14.68

15.03

15.22

15.5

P1796

1-4

11.51

3.0

186.0

15.56

16.30

09

Pedestrian crossing
0.9m CURVED

42mm O.D. SPIGOT

OUTREACH

34

26

10

SPIGOT PLAN

3.0m

46

1 B.S.P.
SOCKET FOR
BEACON

21

1 BSP
TAPERED
THREAD
25

5.8m

MOUNTING HEIGHT

SPIGOT ELEVATION
SCALE NTS

GEAR
OPENING
300

25mm (1)
BSP SPIGOT

450

1.0m

GROUND
PLANTED

GROUND LEVEL

30

CABLE ENTRY
SPIGOT DETAIL
SCALE NTS

Benefits
The CSP Pacific Oclyte pedestrian crossing pole
offers the following benefits:
Aesthetics Continuously tapered octagonal shape
provides a visually pleasing form.
Versatility Due to modular construction, gear opening
position, direction of spigot for Belisha beacon and outreach
direction can be varied to suit the installation as required.

10

Modular The pole consists of three sections which simply

friction-fit together. Assembly, transportation and storage
costs are thus minimised, and only damaged sections need
to be replaced
Safe design Light weight galvanized steel construction
minimises both personal injury and property damage if
struck by a vehicle.

Oclyte

tm

Lighting
Columns

Subdivision column
Benefits

OUTREACH
10
34mm O.D.
SPIGOT

CSP Pacific has designed the Oclyte Subdivision

column as an answer to the increasing costs of land
sub-division and to meet modern road safety and
aesthetic requirements.
Lightweight
Because the Oclyte subdivision column is less than 50 kg in
weight, installation costs can be greatly reduced. Columns can
be lifted and erected by two men without special lifting gear.
Modular

0 3.6m
MOUNTING HEIGHT

The pole consists of sections which simply friction-fit together.

Assembly, transportation and storage costs are thus minimised.
Aesthetics
Continuously tapered, octagonal shaped from spigot to base
provides a visually pleasing form.
Competitively Priced
Automation of production on a standard unit and large
production runs, combined with low installation cost, provides
the client with a competitively priced column.

1 3.6m

Safe Design
Light weight galvanized steel construction minimises both
personal injury and property damage if struck by vehicles.

GEAR OPENING

0.6m

Uses
Residential sub-divisions, retirement villages, hospitals, military
camps.

GROUND
PLANTED

0.6m

GROUND LEVEL

CABLE ENTRY

DWG No.

Elements
Utilised

Planting
Depth

Weight
Column Only
(kg)

0.9

P461

0-1

1.0

38.0

6.0

1.5

P1774

0-1

1.0

38.0

7.3

0.9

P547

0-2

1.3

53.0

7.3

1.5

P1679

0- 2

1.3

54.0

Mounting
Height

Outreach

6.0

(m)

11

1720

00

Standard outreaches
2200

150

10
SPIGOT DETAIL

curved

4000

elliptical
2900

10
1800

1050

4000

(STANDARD
(STANDARD
TILT - TILT OTHER
TILTS ARE
OTHER
TILTS ARE
AVAILABLE)
ALSO ALSO
AVAILABLE)

10
2470 2470

600 LONG SPIGOT

25

25

STANDARD
34 OR
STANDARD
34 OR
42 SPIGOT
42 SPIGOT

10

2200

00

2050

150

1950

1720

2200

00

150

10

SPIGOT DETAIL
0

0
SPIGOT DETAIL
SEE DETAIL
SEE DETAIL
A
A

1800

4330

4330

2900
2900

600 LONG SPIGOT

1

50

50

2050

600 LONG SPIGOT

1950

2050

BUTT WELD
BUTT WELD

SECTION
1
SECTION
1

4000

COUPLING
LINERLINER
COUPLING

282

282

SECTION
0
SECTION
0

DETAIL
A
DETAIL
A

2200

2470

600
LONG SPIGOT

1870

00

25

150
STANDARD 34 OR
42 SPIGOT

150

1518

(STANDARD TILT OTHER TILTS ARE

ALSO AVAILABLE)

3050

1518

10

10

SPIGOT DETAIL
17

SPIGOT DETAIL

2900
SEE DETAIL
A
1800

50

53

1520

MITRE DETAIL
SECTION 1

282

17

COUPLING LINER

SECTION 0

SPIGOT DETAIL
4000

DETAIL A

3050

4000
1000

2058

00
17
0
SPIGOT DETAIL

4000

12
MITRE
WASHER

1660

150

1000

00

2058

1518

1870

1000

600
LONG SPIGOT

150

MITRE
WASHER
SEE SPEC.
0
1660

1660

.5

600
LONG SPIGOT

1870

BUTT WELD

3050

600 LONG SPIGOT

2000

MITRE
WASHER
1
SEE SPEC.

1870

00

3050

2000

1520

1000

2050

4330

mitred

.5
53

MITRE DETAIL

Oclyte

tm

Alternative outreaches
Double Outreach

Lighting
Columns

stand-off bracket

(Post or Wall Mounting)

Triple outreach

13

Floodlighting Columns

14

Floodlight Columns
and Cross Arms

Oclyte

tm

Lighting
Columns

FLOODLIGHT COLUMNS - GROUND PLANTED

Noiminal
Mounting
Height
(m)

Column
Gauge

Elements
DWG NO.
Utilised

Planting
Depth /
Hda
(m)

Column
Weight
Only
(kg)

4.2

2mm

P1552

1-1/2 2

0.9

41.0

5.7

2mm

P1335

1-2

1.2

63.0

5.7

2&3mm

P1804

1-2

1.2

81.0

5.7

3mm

P2253

1-2

1.2

92.0

7.0

2mm

P1553

1-2/3 3

1.9

86.0

7.0

2&3mm

P1805

1-2/3 3

1.9

115.0

8.5

2mm

P1347

1-3

1.7

112.0

8.5

2&3mm

P1806

1-3

1.7

136.0

9.7

2mm

P1334

1-1/2 4

1.9

141.0

9.70

2&3mm

P1807

1-1/2 4

1.9

179.0

9.7

3mm

P1808

1-1/2 4

1.9

208.0

11.2

2mm

P1765

1-4

2.2

173.0

11.2

2&3mm

P1333

1-4

2.2

227.0

11.2

3mm

P1809

1-4

2.2

256.0

12.2

2mm

P1514

1-1/2 5

2.5

208.0

12.2

2&3mm

P1764

1-1/2 5

2.5

278.0

12.2

3mm

P1766

1-1/2 5

2.5

307.0

13.7

2mm

P1554

1-5

2.8

247.0

13.7

2&3mm

P1767

1-5

2.8

311.0

13.7

3mm

P1768

1-5

2.8

364.0

14.7

2mm

P1769

1-1/2 6

3.0

286.0

14.7

2&3mm

P1770

1-1/2 6

3.0

371.0

14.7

3mm

P1771

1-1/2 6

3.0

424.0

16.2

2&3mm

P1555

1-6

3.2

436.0

16.2

3mm

P1773

1-6

3.2

489.0

Note: Standard holding down bolt assemblies available

or special ground stubs.

PLAN

ELEVATION

SMILEY FACE CROSSARM OPTION

15

Seesaw lowering column

Description

NOMINAL MOUNTING HEIGHT TO SUIT

16

Columns are available in mounting heights generally as shown

on page 13. Both ground planted and flange mounted are
available.
The counter-balanced mast is lowered by simply loosening the
securing bolt and attaching a length of rope to the eyelet to
control the lowering of the column.
The only tools required are a spanner, length of rope and
occasionally a short ladder. No bucket trucks, cranes, climbing
rungs, hydraulics or springs, winches or other hoisting gear.

Oclyte

tm

Planting options

Lighting
Columns

17

Holding-down assemblies
Typical Square Type

18.1m NOMINAL MOUNTING HEIGHT

B CRS

D mm PLATE

C I.D.

SLOTTED HOLES
FOR HOLDING
DOWN BOLTS

Typical Circular Type

GEAR
OPENING

6
OUTSIDE

1050

PCD
INSIDE

GROUND LEVEL
POLE SECTION

NON-SHRINK
GROUT
18

8x BOLT HOLE FOR HOLDING

DOWN ASSEMBLY BOLTS

25mm PLATE

Oclyte

Oclyte column
identification

tm

Lighting
Columns

CROSSARM TYPE
STEEL THICKNESS OF
THE SECOND SECTION
AT THE FIRST LAP
F.L.C

OUTREACH TYPE
& SIZE

mm

ESTIMATED
SECTION LENGTH
m

AT FIRST LAP OF
S=
LOWER SECTION

S.L.C

mm
DETAIL A

No. OF SECTIONS
EXCLUDING OUTREACH
CSP TO COMPLETE

MOUNTING
=
HEIGHT
STEEL THICKNESS
AT GEAR OPENING
(BOTTOM SECTION)

AT GROUND LEVEL
(OR AT BASE FLANGE LEVEL)

mm

GEAR OPENING
WIDTH

H = FLANGE
THICKNESS
mm
DETAIL B

mm
G = BOLT CENTRE
MEASUREMENT

F = BOLT CENTRE
MEASUREMENT

mm

mm

K
GEAR OPENING
HEIGHT

mm
S

FIRST LAP FROM G.L.

DETAIL A

DISTANCE TO FIRST
LAP FROM G.L.

S=

mm

G.L.

J = FLANGE WIDTH
OR DIAMETER
DETAIL B

GROUND
PLANTED

mm

GROUND
STUB

HOLD DOWN
ASSEMBLY

19

Assembly and
Standard ground
installation
instructions
planted

20

Assembly and
installation instructions

Oclyte

tm

Lighting
Columns

1)General

4) Assembly equipment

Oclyte poles are made up of tapered eight sided

(octagonal) sections. The standard lengths of these
sections are 3.6m and 1.8m, other lengths are possible
depending on the nominal mounting height of the
column. The column height is achieved by joining
these sections together, the smaller end of one section
slipping into the larger end of the one above. This then
creates a friction joint between the town sections, the
length of this joint is designed to be between 1.5x and
1.6x the AF (across the flats) dimension of the female
section. See fig. 1 below.

a)
General (all columns):
Wire cutters to cut pack straps
Timber bearers
Sledge hammer and timber packing
Tape measure and marker pen

FIGURE 1.

MALE SECTION
FEMALE SECTION

AF

1.5 AF

This friction joint is sufficient as a stand alone joint, nothing else

is needed for strengthening. A silicon sealer can be used to
prevent capillary action of water up through the joint. (Contact
CSP Pacific for further information). The #1 section is always at
the top of column, onto which the outreach (Street light column)
or cross-arm (flood light column) is attached.

2) Receipt of consignment
Please check the consignment carefully to ensure that the
components are correct for quantity, type and condition before
signing off the consignment note or waybill.

3) Assembly methods
There are three main methods that can be used to asseble
Oclyte columns, the type of column to be assembled will
determine which method is used. The three methods are:
Sledge Hammer method (refer to 5.1) column height up
to 12m & steel thickness of 2mm
The Strop method (refer to 5.2) mainly for attaching
streetlight outreaches, or for column height up to 12m &
steel thickness of 2mm
The Winch method (refer to 5.3) column height above
12m or steel thickness 3mm or thicker
Always commence the assembly with the base section. The
assembly procedure requires the column to be assembled one
section at a time (fully tighten each lap joint before progressing
to the next section). Monitor the column at all times during
assembly, to ensure it remains straight in both horizontal
and vertical planes. Before assembly begins ensure that the
following preparations are done:

b) 
Streetlight columns incorporating an outreach arm
All general equipment as above
Street wire rope(1) (the approximate length required
equals the mounting height of the column plus the
outreach length plus 1m)
2 tonne Tirfor winch(1)
Soft strop(2)
Note(1): Items 2 and 3 are optional. Needed for Winch
method only.
Note(2): Item 4 is optional. Needed fro Strop method only.
c) 
High Masts columns 12m mounting height or
higher and/or 3mm steel gauge or thicker.
All general equipment as above
Steel wire Rope (approximate length required equals
the length of the column plus 3m)
One or two 5 tonne Tirfor winches or rigger hoist.
(two generally needed for columns 30m in height or
higher and/or 6mm steel gauge or thicker)
Tirfor frame

5) SITE PREPARATION
Assembly should be undertaken on a level platform and with the
pole base as close as is practical to the prepared foundation.
Initial preparations
Ensure all lap surfaces are free from obstructions e.g. dirt,
stones, dents, galvanizing/weld lumps etc.
Mark out the distance (1.5 x AF) on the male section prior
to assembly as a guide to the actual overlap achieved.
Also make an additional mark +100mm on small columns
and +200mm on large columns, which is to be used as a
reference mark, in case the design lap mark is exceeded.
The lap length should be between 1.5 and 1.6 times the
AF or across the flats dimension of the inside of the
female section at the bottom. The minimum acceptable lap
is 1.4 x AF. Please contact CSP Pacific if you are unable to
achieve the minimum lap (ph: 0800 655 200).
Support the sections on bearers and ensure that they are
aligned for ease of mating.
Ensure that each pole sections seam weld is aligned with
the adjoining one. (Note that this does not necessarily
apply for the joint of the top section to the outreach). When
climbing rungs are supplied, make sure that these are
aligned as well (right hand side rung on the upper section
succeeds left hand side on the lower one or visa versa).

21

Assembly and
installation instructions
5.1) Sledge hammer method
The following procedure applies to the OclyteTM columns of
approximately 12m or less in mounting height manufactured
in 2mm steel gauge. For floodlight columns incorporating a
cross arm, steps 6 and 7 are to be ignored.
I) Ensure initial preparations are complete as per above.
II) Place the bottom end of the bottom section against
a firm support. Use timber packers in between if
there is no flange (e.g. ground planted column). Start
hammering the top of the second section via a timber
packer. Timber packers are needed to avoid damaging
(buckling) the slender walls of the column.
III) During assembly, the joint must be agitated to facilitate
mating. This can be achieved by tapping around the
joint area using a sledge hammer (or similar) and timber
packer.
IV) Ensure that the required lap is achieved.
V) Continue with the consecutive sections in the same
manner, until the column is fully assembled.
VI) Place the outreach against a firm supports as shown in
Figure 2. Advance it to the top section and engage the
two ends together as far as is possible ensuring that the
column and the outreach are aligned straight. Support
the column on timber bearers.
VII) Hammer the bottom of the column using a timber
packer. Push the outreach firmly against the supports
(fig. 2) and hold it like that. This is to prevent any
movement of the outreach during hammering of the
sections on it.
VIII) The cross arm (if applicable) must be attached last

PUSH THE OUTREACH

FIRMLY AGAINST
THE SUPPORTS

USE TWO SUPPORTS FOR THE OUTREACH

e.g. A WALL, TRUCK TYRES, A TREE,
A KERB OR SIMILAR ITEMS.
TIMBER PACKER

TOP OF
PRE-ASSEMBLED
COLUMN
LAP MARK

FIGURE 2.

SIDE SUPPORT IF NEEDED

(STAKE DRIVEN INTO
GROUND OR SIMILAR)

5.2) STROP METHOD

The strop method is generally only used for attaching the
outreach to a fully assembled streetlight column, although
the technique can be used to assemble pole sections as
well.
Assemble all the sections except the outreach together
using either the Sledge hammer or the Strop Method.
Attach the outreach as follows:

22

I) Support the base of the bottom section against a firm

support. Advance the outreach to the top of the top section
and engage the two ends together as far as possible. Use
timber packers at the bottom if there is no flange base (e.g.
ground planted column).
II) Wind the strop several times around the straight portion of
the outreach near the lap. Pull the strop towards the bottom
of the column until the required overlap distance is achieved.
During pulling, the joint must be agitated as described
before
For pulling the strop down, depending on the equipment
available, there are two options:
A hiab truck can be used and the strop can be pulled by the
lifting arm (fig. 3); or
A tirfor winch can be used for pulling the strop.
Note:
Apply the force as centrically as possible when pulling the
outreach on to the column

FIGURE 3.

5.3) WINCH METHOD (FOR ANY STEEL GAUGE)

The following procedure applies to OclyteTM columns of
medium and large size, i.e. approximately 12m mounting
height or higher and/or 3mm steel gauge or thicker. Street
lighting columns are not covered by the procedure below.
I) Assemble the tirfor and the frame at the base of the
bottom section. Feed the cable through the centre
looping it at the top end of the adjoining section around
a rigid bar bearing on the section (Figure 4). Ensure that
the bearing of the bar will not damage (buckle locally)
the top of the section during winching (e.g. use timber
packers). Also use timber packers at the bottom if there
is no flange base (e.g. ground planted column).
II) During winching, if needed, the joint can be agitated
to facilitate mating. This can be achieved by tapping
around the joint area using a wooden hammer (or
similar).
III) Continue winching until the lap is fully tight, and
will close no further. Ensure that the required lap is
achieved. (Stop further winching if it causes column
to bow significantly, which can occur with slender
columns).

Assembly and
installation instructions

IV) Continue with the consecutive sections in the same

manner, until the column is fully assembled.
V) The cross arm is attached last.

Note:
Monitor the column at all time during the winching procedure, to
ensure it remains straight in both horizontal and vertical planes.
LOOP OF WIRE ROPE
SECURED TO STEEL BAR
SECOND
SECTION

BOTTOM
SECTION

STEEL WIRE
ROPE
TIRFOR WINCH
OR RIGGER HOIST

PULLING
FRAME

BEARERS

FIGURE 4.

6)Climbing rung assembly

(if applicable)

I) Screw M24 and plain washer onto the onto the climbing
rung as far as possible.
II) Slide the other nut up the inside of the climbing rung
bracket on the pole section and hold in position.
III) Screw the climbing rung all the way into the second nut
in the climbing rung bracket.
IV) Tighten outer nut against the climbing rung bracket until
it lock the locks the rung.

Notes:
Always ensure that the climbing rung up-stand is vertical
before tightening the nut.
Refer to Figure 5 for the climbing rung assembly
221
150

MIN. POLE SECTION 3mm GAUGE

POLE
SECTION

W
 eb strop and/or steel wire rope or similar.
2 x Heavy duty spanners suitable for the holding down
nuts (for flange mounted columns).
Spirit level
Torque wrench
Lubricating oil for bolt threads

7.2) Preparation prior to erection

Prior to erection the column must be completely assembled.
Use the template (if supplied) to check holding down bolts
are in the correct position. Check whether all bolt and nut
threads are clear and undamaged and apply small amount
of lubricating oil to bolt threads. Level the lower set of nuts
on the holding down bolts.
The recommended point of lifting is approximately 2/3 up
the height of the pole. This is well above the centre of gravity
which is approximately 2/5 of the pole height from the base.
It should be noted that lifting point for some large columns
with big head frames can be different from the above and
special erection instructions are generally issued in such
cases
Attachment of the lifting hook to the pole can be achieved
using a web strop or similar, wound twice around the
octagonal section in such a manner that it will not slip
upwards when lifting commences. Locating this strop just
below the lap joint of a section, below a climbing rung or
other attachment is advisable.
Prevent sudden jerking movements during erection as this
may cause sections to loosen. This will not easily occur. As
a safety precaution a cable or strop should be attached at
the lifting point, then wrapped tightly around the column a
few times and attached near the base. The attachment point
used at the base depends on the size of the column. For
smaller and medium columns, the cable can be hooked into
the gear opening. For larger columns the cable should be
hooked to a stronger attachment point (e.g. an earth lug at
the base). (fig. 6)

24mm DIAMETER GALVANIZED

BAR c/w M2470mm THREADED
END PART No. :2110049

CLIMBING RUNG BRACKET

30

MIN. POLE SECTION 3mm GAUGE

SIDE ELEVATION

Lighting
Columns

If there is no access to the lifting point after erection, make sure

that the web strop is long enough to slip down the pole after
being loosened after the column is installed.

80

2 GALVANIZED NUTS
AND ONE PLAIN WASHER

tm

Note:

MIN. RADIUS

38

90

POLE
SECTION

Oclyte

PLAN ELEVATION

THIS OPTION IS TO BE USED FOR LONG COLUMN LENGTHS

FIGURE 5.

7)Erection / lifting of assembled Oclyte

columns
Two types of poles are available, ground planted and flange
mounted. The latter has a flange welded to the bottom section
and is either bolted to a hold down assembly (HDA) that has
been cast into a concrete foundation or bolted onto the flange of
a ground stub. The basic recommended erection procedure for
both these are primarily the same

7.1) Lifting equipment

FIGURE 6.

THIS OPTION IS TO BE USED FOR SHORT COLUMN LENGTHS

 rane, Hiab or similar lifting machine is used to erect the

C
column. The lifting machine should be adequate for the
pole weight and length. (A 30m pole will ordinarily require
a 18m jib and a rated lifting capacity of 12-15 tons).

23

Assembly and
installation instructions
8)Erection procedure flange base
columns

I. Mark the baseplate hole and the matching holding down

bolt prior to lifting.
II. Lubricate the threads of the holding down bolts with a
Holts lube stick (or similar lubricant) to ensure nuts are
free running.
III. Position the crane 6-8m from the centre of foundation
to centre of the jib turntable. Plan the operation so that
the column is lifted at approximately the same jib radius
needed for placing it over the foundation. (See fig. 7).
IV. Check column balance position and commence lifting
slowly - slewing jib continuously or frequently, in order to
keep hoisting rope vertically.
V. When column is standing almost upright, firstly hoist
it clear of the ground, then lower it very slowly into
position over the foundation.
VI. By manual means make last positional adjustments so
that holding down bolts are aligned with the correct
holes.
VII. Gradually ease the pole down until at least 2 nuts can
be adequately engaged, taking care not to damage the
threads. Do not lower further - first, slew a little to the
right to bring the pole vertical.
VIII. Lower onto all holding down bolts and adjust levelling
nuts to ensure correct pole alignment.
IX. Fit the top set of nuts. Unless specified otherwise, all
nuts are to be tightened to Snug Tight as described
in clauses 9.2 & 15.2.5.2 NZS3404 (1997) (Snug tight is
the tightness that can be achieved by a person using
a standard length, 450mm, Podge spanner or by a few
impacts from an impact wrench).
X. After tightening to snug tight, the top nuts are to be
loosened, and then retightened back to snug tight (this
process ensures the Galvanized layers on the fasteners
has been compressed).
XI. Finally grout under the base using a non shrink grout
(SIKA GROUT 212 or equivalent) unless specified
otherwise

Note:
Avoid sudden movements during lifting procedure, as this
may cause sections to become loose (if lap joints are not
fully tight) or may cause local buckling at the attachment
point
Care is required in selecting the location of the lifting point
with columns that have proportionally large attached mass
at, or near the top of the column.

24

FIGURE 7.

9)Erection procedure - ground planted

columns and columns completed with
ground stubs
The depth of the ground-planted section is nominally equal to
1/6th of the total length of the column or 1/5th of the nominal
mounting height of the column (height above ground level). In
case of streetlight columns this is the vertical distance to the top
of the outreach.
CSP Pacific recommends the following:
Unpainted ground section - use of low grade concrete as a
backfill material.
Painted ground section - use of low grade concrete or
granular backfill.
I. The minimum diameter of the planting hole is equal to the
across the flats (AF) dimension of the column at the bottom
of the planted section plus 200mm.
II. Backfill the hole in layers of up to 150mm each and compact
each layer individually.
III. Finish the backfill in a conical shape (See fig. 8)
Notes:
Ground planting requirements for most Oclyte columns
will be covered by the above recommendations however,
responsibility for determining the required ground planting
details rests with the user. This is due to the large number of
variables including diameter of the column, number and size
of the attachments, wind conditions, soil conditions and the
type of backfill material used

Assembly and
installation instructions

Oclyte

tm

Lighting
Columns

Avoid using soil for backfilling as it may cause corrosion

When concrete is used as a backfill, allow sufficient time for
it to set (as per the concrete suppliers instructions) before
loading
CSP PACIFIC
STREETLIGHTING COLUMN

GEAR OPENING

GROUND LEVEL
EPOXY PAINTED STRIP

GROUND PLANT DEPTH

AS PER RECOMMENDATIONS

100

CSP PACIFIC
STREETLIGHTING COLUMN

15075 CABLE
ENTRY HOLE

100

SELECTED GRANULAR BACKFILL

MINIMUM HOLE DIAMETER
POLE BASE WIDTH +200mm

HOLE =
POLE WIDTH +200mm

FIGURE 8.

10)Plumbing in warm weather

In warm and hot weather poles become hotter on the side facing
the sun. Due to thermal expansion differences a temporary
curvature of the pole could occur, which can be best seen by
viewing the pole from the end. Pole plumbing in such weather
conditions should be done early or late in the day.

25

Shear base assembly,

installation and maintenance
Shear base poles
Shear base (Slip Base) poles are a very effective way to reduce the probability of severe injury to vehicle occupants.
A characteristic of shear base poles is that, when impacted at normal urban operating traffic speeds, they are generally dislodged
from their original position.

To ensure that a shear base pole performs in the designed manner, it is important that the pole be installed correctly.
Alignment of the shear base flange to the traffic flow should
be as per diagram 2. Ensure that the flange is levelled.
The ground stub should be backfilled with concrete to the
outside ground level using 17.5MPa concrete. To delay
corrosion, concrete can be put on the inside of the ground
stub. However, if concrete is placed inside the ground
stub, it is very important that the level should be just below
the drainage holes near the top of the stub, with the top
mounded to aid in water drainage. This prevents water from
permanently sitting inside the stub, leading to accelerated
corrosion see diagram 1. Ensure that the top face of the
flange is cleaned of any concrete following pouring.

BOLT TORQUE
250Nm PRE-TORQUE
90 TO 100Nm FINAL
6 MONTHLY INSPECTION
STREETLIGHTING COLUMN

SHEAR BASE ASSEMBLY

75

GROUND LEVEL

MOUND CONCRETE
INSIDE GROUND STUB TO
UNDERSIDE OF DRAIN HOLES

GROUND STUB

CABLE ENTRY HOLE

Prior to erection ensure that all components are present and

clean - diagram 4.

Position the pre-assembled pole over the ground stub

flange, ensuring that the tab washers are not knocked out
of alignment.
Terrain in the vicinity of the shear base ground stub must
be graded to allow a vehicle to pass over the stub without
interference, and also to avoid the vehicle becoming
airborne prior to impacting the column. Generally a negative
slope of 1:6 should not be exceeded. The ground stub
should not protrude more than 75mm on horizontal ground
conditions or 100mm above the ground line over a horizontal
span of 1.5m - see diagram 1 and 3.

DIAGRAM 1

The shear base connection is to be inspected every 6

months, or after significant weather events (severe wind
speeds). Each bolt is removed, checked for condition
(fatigue cracking, corrosion etc.) and then re-installed as
per previous assembly notes. If there is any sign of fatigue
damage to the bolt, the bolt must be replaced. Adequate
column supports or baseplate clamps must be provided
during the inspection process.
STREETLIGHTING COLUMN
SHEAR BASE ASSEMBLY

15

NOTCH FOR
OUTREACH DIRECTION
GALV
VENT HOLE

DIAGRAM 2

10 0m
MA XIM m
UM

Lubricate the M24 x 110mm bolts with a suitable lubricant

such as Loctite Heavy Duty Anti-Seize stick, Loctite
Silver Grade Anti-Seize Lubricant pouch or Holts Lube
Stick. Ensure that all parts of the thread are covered.
For easy installation insert the bolts so that the nuts are
facing upwards, see diagram 4 and then tighten to 250Nm
minimum torque. Slacken off and re-torque to 90100Nm immediately or, at the very least, before the
road is opened. If the bolts are left tighter than about 90100Nm, the shear base will not perform as required in the
event of being struck. Correct alignment of all components
should be checked at this stage. Using locknuts is also
recommended.

1500 SP
AN

GROUND LEVEL
1:6 MAXIMUM
NEGATIVE SLOPE

6 MAX.
1

DIAGRAM 3

26

DIRECTION OF
OUTREACH

GEAR OPENING

DIRECTION OF
TRAFFIC FLOW

Position the tab washers on the lower flange and ensure that
the tabs are correctly engaged inside the inner edge of the
flange. This is critical to the functioning system.

17.5 MPa CONCRETE

BACKFILL IN 200 MM
MINIMUM OVERSIZE HOLE

Shear base assembly,

installation and maintenance

Oclyte

tm

Lighting
Columns

Diagram 4

27

Optional corrosion protection

Oclyte Tuff Coat
Oclyte Tuff Coat is a high-performance, twocomponent Polyurethane spray coating that is field
proven world wide for extending the service life of
utility poles beyond the life expectancy of conventional
galvanising.
It is specifically engineered to add corrosion, abrasion and
impact resistance to galvanised steel structures such as:
utility poles, multiplate structures and guardrail components
especially at and below ground level.

Performance testing
This product has been thoroughly performance tested for:
Toughness
Impact
Scratch resistance
Chemical resistance
Corrosion resistance
Adhesion
Cathodic disbondment
Salt spray resistance

Features
Direct to metal application no primer required with
application to mechanically prepared (profile shaping)
galvanised or steel substrates
Green technology 100% solids technology, contains no
VOCs (Volatile Organic Compounds e.g. paint solvent),
styrene or coal tar
Single coat is applied in a single coat with a multi-pass
application to create the required film builds and is five times
thicker than the currently used paint system
Superior scratch and impact resistant due to an
extremely durable polymer membrane, damage is highly
unlikely during handling and/or installation
Chemical resistance provides exceptional chemical
resistance to a wide range of aggressive soils, salts and
other chemicals
Fast cure 10 minutes to handle
CSP Pacific offers a 20 year system warranty

28

In addition CSP Pacific has undertaken comparative

accelerated corrosion testing between the various coating
systems available on the market and the currently used system
See test results, where corrosion was simulated over time.

Optional corrosion protection

Oclyte Tuff Coat

Oclyte

tm

Lighting
Columns

Comparative accelerated corrosion test results

These tests simulated potential damage during installation and handling by scratching the coating on the test pieces down to bare
metal. The coating was monitored over time at the scratched area and the undamaged area.
NB A saw was required to cut through the Oclyte Tuff Coat to expose the metal during testing

Hot Dip Galvanising after 500 hours

of salt spray testing

Oclyte Tuff Coat after 500 hours

of salt spray testing

Hot Dip Galvanising after 1000 hours of

salt spray testing

Oclyte Tuff Coat after 1000 hours of

salt spray testing

Result

Result

Galvanising has sacrificed itself to protect the steel

Excellent adhesion to the surface

After 1000 hours of salt spray testing almost all the

galvanising was gone

5-10mm loss of adhesion at the cut surface area only

4mm start of corrosion at the cut area
Uncut surface is in excellent condition, no corrosion present

29

Standard ground planted

Notes

30

Oclyte

tm

Notes

Lighting
Columns

31

Copyright and Limited Reproduction:

The design of and all content appearing in this brochure are the copyright of CSP Pacific. No part of this brochure may be:
d
 istributed or copied for any commercial purpose, nor incorporated in any other work or publication (whether in hard
copy, electronic or any other form); or
r esold, published, copied, reproduced, transmitted or stored (including in any other brochures or other electronic
form) except that you may print, or copy only for your own use (or for use in any document, proposal or presentation
for the purpose of specifying products manufactured or supplied by CSP Pacific), without the express permission of
CSP Pacific.
Disclaimer:
This Brochure contains files which were current at the time of printing. Latest drawings and information are available in
PDF format from our website www.csppacific.co.nz

CSP Pacific A Fletcher Concrete & Infrastructure Limited business

306 Neilson Street, Onehunga, Auckland 1061, New Zealand
PO Box 12 949, Penrose, Auckland 1642, New Zealand
Ph: 0800 655 200 or +64 9 634 1239Fax: +64 9 634 4525

www.csppacific.co.nz