Geometric Configuration Effects on the Formation of Weld Toe Cracks during the Galvanizing of High Mast Illumination Poles

Cracks at the pole-to-base plate connection of high mast illumination poles (HMIPs) are a major source of concern to highway transportation officials. Thermally induced deformations induced during the galvanizing process are known to introduce damages to the pole-to-base plate connection. In this study, finite element analyses were performed to evaluate the effects of geometric configuration variables on the response of the HMIPs during galvanizing, particularly in determining the stress demand magnitudes. The control variables of the study were base plate thickness, pole shaft wall thickness, and number of pole sides. The numerical results indicated that the stress demands were highest at locations near the pole-to-base plate connection. Reducing the base plate-to-pole thickness ratio and using poles with round shape were identified as effective approaches to reduce stress demands in HMIPs during galvanizing.