Light Pole Base Bolts

[Alwayslearningelec]

So these are set in place by site works contractor and we have to set anchor bolts. Anyone ever do this before? There are 4 in each foundations.

I've never had to labor something like this before. I'd imagine you would set them and then have to wait for the concrete to set? How long you think start to finish to set 4 of them? Thanks

 

[JohnE]

I've never done a lot of pole lighting, but we used to make plywood templates and bolt the anchor bolts to the plywood and set them in the wet sonotube pour and level them. Once the concrete was cured, we'd remove the top bolt and the plywood template, and set the poles.

 

[infinity]

Back in the day we always used plywood. Today there are much fancier options like Bolt Star.

Products

Introducing Bolt Star™ An innovative, multi-function reusable bolt template engineered to hold four anchor bolts, rebar cage and conduits securely in place during the pour of a concrete pole base. …

bolt-star.com

 

[James L]

I've done pole lights, and we were the ones who did all of it. I think it could be a lot different if a site contractor was handling the concrete part

They get poured or pumped out of a truck.

Our boss would schedule the truck and we would meet there at the appropriate time. We'd be done in a couple of hours with two guys

If it's a site contractor, he may be pouring other stuff on the same day and you need guys there the whole time so that when they're ready for the pole bases you're there.

There's just a bit of unknown

 

[Electromatic]

One tip is to put some deox or duct tape or something on the bolt threads before the pour to keep them clean.

 

[Alwayslearningelec]

So if we were setting JUST (4) anchor bolts as shown would 2 men an hour each( so two hours) be doable?

 

[augie47]

So if we were setting JUST (4) anchor bolts as shown would 2 men an hour each( so two hours) be doable?

Using a template, it never took as much as an hour including smoke breaks

 

[tom baker]

Allow several days for concrete to set a week is better. You will want to bolts and layout. Put tape on bolt threads.

 

[James L]

Using a template, it never took as much as an hour including smoke breaks

Yes, not supposed to.

But pushing the bolts/template down into the concrete (the work) is the easy part.

It's the waiting that can kill you

 

[infinity]

Using a template, it never took as much as an hour including smoke breaks

How much time would you estimate to make up the templates?

 

[Alwayslearningelec]

I'm not clear on the template part. What's that process during or before the casting? Thanks

 

[James L]

I'm not clear on the template part. What's that process during or before the casting? Thanks

You make or buy a template so that you can put the bolts into it and lower it into the wet concrete to just the right depth.

You have to line the bolts up in the template to the spacing required for the lights

 

[infinity]

You make or buy a template so that you can put the bolts into it and lower it into the wet concrete to just the right depth.

You have to line the bolts up in the template to the spacing required for the lights

You'll also need a cut out in the center of the template for the conduit.

 

[Rick 0920]

You should have bolt pattern from your fixture submittals. I've always made plywood templates and centered them on the sonotubes. the usually pour them with a pump truck so you can fasten your template down before they pour. put all your hardware over the threads, coat your threads with white bearing grease, (it's much cleaner) and duct tape your threads. No concrete will stick to them.

 

[James L]

You'll also need a cut out in the center of the template for the conduit.

Yes. Good catch

I had that in my response but it started getting long. I missed it in my revision 🫣

 

[James L]

You should have bolt pattern from your fixture submittals. I've always made plywood templates and centered them on the sonotubes. the usually pour them with a pump truck so you can fasten your template down before they pour. put all your hardware over the threads, coat your threads with white bearing grease, (it's much cleaner) and duct tape your threads. No concrete will stick to them.

I've seen guys fasten them down before the pour, and it seems like they're just always a mess later 🫤

 

[hbiss]

I'm not clear on the template part. What's that process during or before the casting? Thanks

You have to cut a piece of plywood maybe 25"x25" for each post. You have to drill holes in them according to the bolt spacing. On the day of the pours one man follows the concrete guys around and when they finish each pour, he embeds the bolts into the concrete using the template for location. The template stays until the concrete sets up.

I'm not seeing any spec for a form, so whoever sets the bolts is going to have to make sure the top is level (which is where the plywood template comes in).

And yeah, don't forget a hole on the center of the template for the conduit.

-Hal

 

[Alwayslearningelec]

Ok thanks a lot. Seems like more than 2 men 1 hour for each pole.

 

[acin]

You make or buy a template so that you can put the bolts into it and lower it into the wet concrete to just the right depth.

You have to line the bolts up in the template to the spacing required for the lights

if inspected bolts have to be secured in form before conc some take bolts out after inspection an wet set

 

[hbiss]

Ok thanks a lot. Seems like more than 2 men 1 hour for each pole.

How long does it take ONE man to make the plywood templates? If you are "mass producing" them maybe 10 minutes each using the first one as a template for the rest?
How long does it take for ONE man to set the bolts in the concrete? 20 minutes each once you are on a roll? You don't say how many posts and where they are, but I suspect the most time will be spent (wasted) in waiting for the concrete guys to go from location to location and finish their pours.

I think you are way off.

-Hal