Fatigue Failure and Cracking in High Mast Poles

mahyarov · 11-13-2012, 10:21 AM

This report presents the findings of a comprehensive research project to investigate the fatigue cracking and failure of galvanized high mast illumination poles (HMIP). Ultrasonic inspection of poles throughout the state has revealed the presence of weld toe cracks at the shaft-to-base-plate connections of some galvanized poles that the Texas Department of Transportation (TxDOT) owns. However, the effect of these galvanization-induced cracks on the fatigue life of the poles has not been clearly defined. The first phase of this research involved extensive review of published and unpublished data, to identify key factors that contribute to galvanization-induced cracking. Best fabrication practices to minimize such cracking are recommended. In the second phase, a comprehensive reliability analysis of several TxDOT pole configurations was conducted for different regions in Texas to predict the fatigue lives of the cracked poles. Critical pole configurations and locations are identified to facilitate cost-effective decisions related to inspection, repair, and replacement of poles.

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