4 minute read
Repair or Replace?
By Kurtis Magargee COO, Light Pole Systems, Inc.
Images Courtesy of Light Pole Systems, Inc.
In the previous articles in this series, we examined how to identify rusted and damaged poles and discussed commonly used testing methods. Here, we take a closer look at pole repair versus pole replacement, highlighting some of the differences and unseen benefits of repair from the contractor’s point of view.
For this discussion, we will use the specific details from one case study that is representative of what’s seen in parking lots across the country. This project was a parking lot LED upgrade replacing 400W metal halides with 150W LED fixtures. The property owner had a preliminary budget for the fixture replacement but had not considered the poles until one fell, prompting him to inspect the rest of the poles on the site.
Luckily, one of the contractors bidding the project was a NALMCO member and understood the value of pole inspection. They inspected the entire property, finding that all of the poles were in some form of decay, from marginal to hazardous. The cost of replacing the poles far surpassed the maintenance budget and threatened to delay the project until next budget cycle.
Using pole repair kits to repair the existing poles and packaging the pole repair with the LED upgrade, they were able to convert the repairs to a capital expense and keep the total expense within the property owner’s capital budget.
Now that we have an idea of the project, lets look at the details of the poles. The total project consisted of 37 pole repair kits, 1 new pole, 38 decorative base covers, and 5 drill and epoxy anchor bolt kits.
The poles are simple 4-inch square steel 20-foot poles with one or two fixtures in parking lot islands or along walkways. The contractor specialized in LED upgrades and elected to run two crews: the first to repair the poles with the pole repair kit, and the second to install the new fixtures. They only needed a crane to install the one pole that was destroyed. All other aerial work was done with a less expensive self-propelled man lift.
The contractor budgeted both new poles and pole repair kits.
The new pole option increased part and labor cost by 50%, which brought the total project cost up by the same margin. The property owner elected to use the pole repair kits for the lower cost, but more importantly, the shorter lead time. Pole repair kits allowed them to use their own crews and equipment. Specializing in LED retrofits, they do not own a crane to stand poles or have many technicians qualified to do this work. They were able to keep their crews doing the type of work they specialize in, and their overall profit was higher.
PROJECT BREAKDOWN
THE POLE REPAIR
Pole repair kit: $598 (including all needed hardware)
Cone Base Cover: $99
Miscellaneous tools: $7 (total cost divided by 37 locations)
30 minute install per pole with a 2-man crew
Total contractor cost per pole: $704 and 1 man-hour.
THE POLE REPLACEMENT
New 4” square, 20’ pole: $680
Crane service: $300 (2 hours/pole, $150/hour)
2 hours per install, 2 man crew
Total contractor cost per pole:$980 and 4 man-hours.
The costs and time estimate for installation will vary depending on region and how the contractor is set up. This breakdown assumes regular pole work and low-cost crane rental.
There were five locations, including the new pole, that required new drilled and epoxied anchor bolts. The base of the pole repair kit includes additional holes for the new anchor bolts at no additional cost. The new pole included a custom base plate with additional holes for new anchor bolts at an increased cost of $819.
The pole repair kits are designed to repair rusted poles without disconnecting the electrical wiring or removing the pole. The cost savings increases exponentially on larger 5” and round tapered poles. Pole repair kits are in stock for 4” and 5” round or square poles, and round tapered poles. Other custom sizes are available.
The decision of whether to repair or replace poles should be made by a qualified on-site technician who has inspected each pole. In this case, repairing the poles was a viable option for all but one, leading to a smaller upfront cost and quicker turnaround time on the project.
Light Pole Systems is available to answer any questions about pole repair and pole replacement. Find more information or contact them through their website.
Five pole locations required new drilled and epoxied anchor bolts, accommodated by additional holes in the pole repair kit.
