Precast Prestressed Concrete Street Lighting Poles
1986 Edition

Summary of IS 2193 Key Requirements & Reference Tables

Scope (Clause 5.4 and related sections)

• Distance from Luminaire Mounting Point to Light Source Center (Table 2):

*Distances vary depending on specific design parameters.

• Bracket Outreach Lengths (Clause 5.5, Table 3):
  Standard outreach is determined by pole height (refer IS 2193 Table 3 for detailed values).

• Sampling and Quality Control (Clause 9.1.3, Table 4):

• Note: Poles or brackets tested up to the first crack may be reused if the cracks close after unloading.

These specifications ensure optimal luminaire positioning and robust quality control during manufacturing.

IS 2193 Material Requirements & Standards

1. Aggregates (Clause 4.2):

• Must conform to IS 383:1970.
• Maximum aggregate dimension: 20 mm.
• Purchaser approval may be required for samples.

2. Cement Types Referenced:

• Ordinary and Low Heat Portland Cement (3rd revision)
• Portland Slag Cement (3rd revision)
• Portland Pozzolana Cement (2nd revision)
• Rapid Hardening Portland Cement (1st revision)
• Hydrophobic Portland Cement (1st revision)
• High Strength Ordinary Portland Cement

3. Concrete Standards (Clause 4.4):

• Prestressed concrete: follow IS 1343:1980.
• Reinforced concrete: adhere to IS 456:1978.

Key Reference Table:

Sampling & Inspection (Clause 9.1.3, Table 4)

Summary

• Use aggregates complying with IS 383 with max size 20 mm.
• Cement as per specified IS codes.
• Concrete mixes follow IS 1343 for prestressed and IS 456 for reinforced concrete.
• Sampling as per Table 4 ensures compliance and durability.

Manufacture Guidelines per IS 2193: Key Specifications & Tables

1. Luminaire Support Distance to Light Source (Clause 5.4, Table 2)

*Distances vary depending on exact pole height.

2. Sampling and Acceptance Criteria (Clause 9.1.3, Table 4)

• Note: Poles tested up to first crack may be reused if cracks close on unloading.

3. Materials

• Aggregates must meet IS 383:1970 requirements with a maximum size of 20 mm.
• Cement types as per relevant IS specifications.

Illustrative Diagram: Luminaire Distance

graph LR
A[Pole Height] --> B{Luminaire Type}
B --> C[Top Entry Luminaire]
B --> D[Side Entry Luminaire]
C --> E[Distance Range: 300-450 mm]
D --> F[Distance Range: 100-150 mm]

This framework ensures the proper design and quality during the manufacturing process.

Summary of Reinforcement Criteria per IS 2193

Applicable IS Standards for Reinforcement:

• IS 432 (Parts 1 & 2): Mild steel and medium tensile bars, as well as hard-drawn wire used in concrete reinforcement.
• IS 1785 (Parts 1 & 2): Plain hard-drawn steel wire for prestressed concrete.
• IS 2090: High tensile steel bars for prestressed applications.
• IS 6003: Indented wire for prestressed concrete.
• IS 6006: Stress-relieved, uncoated strands for prestressing.

Key Requirements:

• Reinforcement bars and wires must comply with the above IS standards.
• High tensile wires should have diameters ranging from 3 mm to 5 mm; grouping of wires is allowed.
• Surfaces must be clean, free from loose rust, oil, grease, or dirt; slight rust is acceptable.
• Precise placement and secure fixing of reinforcement and ducts during casting is essential.

Concrete Compatibility:

• Prestressed concrete: as per IS 1343:1980.
• Reinforced concrete components: as per IS 456:1978.

Typical Reinforcement Details:

Diagram:

flowchart TD
    A[Reinforcement Bars/Wires] --> B{Conformance to IS Standards}
    B --> C[IS 432 Parts 1 & 2]
    B --> D[IS 1785 Parts 1 & 2]
    B --> E[IS 2090, 6003, 6006]
    A --> F[Diameter between 3-5 mm for High Tensile Wires]
    A --> G[Surface Cleanliness with Slight Rust Allowed]
    A --> H[Precise Positioning During Manufacture]
    H --> I[Concrete as per IS 1343 and IS 456]

This ensures reinforcement integrity and compatibility with concrete standards.

Core Design Parameters from IS 2193

1. Distance from Luminaire Support to Center of Light Source (Clause 5.4, Table 2)

*Distances subject to purchaser's specifications.

2. Minimum Embedment Depth for Prestressed Concrete Poles (Clause 5.3, Table 1)

3. Concrete Standards (Clause 4.4)

• Prestressed concrete poles as per IS 1343:1980.
• Reinforced concrete components as per IS 456:1978.

Design Parameters Diagram

graph TD
    A[Pole Mounting Height] --> B[Distance to Light Source]
    A --> C[Embedment Depth]
    B --> D[Top Entry Luminaire]
    B --> E[Side Entry Luminaire]
    C --> F[Minimum Depth per Table 1]

Use these tables and clauses to guide structural design and installation of street lighting poles according to IS 2193.

IS 2193 Specifications for Pole Dimensions and Openings

Key Points (Clause 6.4 & 6.4.1)

• Door Opening Dimensions: To be mutually decided by manufacturer and purchaser.
• Door Construction: Weather-resistant with a locking mechanism to prevent unauthorized access.
• Door Position: Bottom edge placed at a minimum of 300 mm above ground level.

Luminaire Mounting Distance Reference (Clause 5.4, Table 2)

*Distances vary based on design specifics.

Summary

• Doors must be lockable, weatherproof, and start at least 300 mm above ground.
• Luminaire distances depend on pole height and luminaire type.

flowchart TD
    A[Pole Base] -->|Min 300 mm| B[Bottom of Door Opening]
    B --> C[Door Opening (Size per Agreement)]
    C --> D[Weatherproof Door with Lock]
    D --> E[Luminaire Support]
    E -->|Variable Distance by Height| F[Light Source Center]

These provisions guarantee secure and functional pole design.

IS 2193 Guidelines on Curing and Concrete Cover

1. Curing Procedures (Clause 7.7)

• Concrete surfaces to be covered with absorbent materials such as sacking, canvas, or hessian.
• Cover must remain continuously moist until:
  • Poles achieve minimum strength required at prestress transfer.
  • Reinforced concrete brackets reach adequate strength.
• Post-mould removal, surfaces should be periodically wetted to prevent cracking, frequency depending on ambient humidity and temperature.
• Steam curing may be used as an alternative method.

2. Concrete Cover Requirements (Clause 7.4)

• For pretensioned tendons:
  • Minimum cover to tendon exterior: 20 mm.
  • For cables or larger bars: minimum cover of 30 mm.
• Minimum clear spacing between individual wires:
  • At least one-third of the maximum aggregate size and
  • At least three times the wire diameter.
• Clear distance between cables or large bars:
  • Minimum of 40 mm or
  • 6.5 mm plus largest aggregate size, whichever is greater.

3. Aggregates (Clause 4.2)

• Aggregates must conform to IS 383-1970.
• Maximum size: 20 mm.

Summary Table for Covers & Clearances

flowchart TD
    A[Curing Process] --> B[Cover with Absorbent Material]
    B --> C[Maintain Continuous Moisture]
    C --> D{Strength Achieved?}
    D -- No --> C
    D -- Yes --> E[Remove from Mould]
    E --> F[Periodic Watering to Prevent Cracks]

    G[Concrete Cover] --> H[20 mm for Pretensioned Tendons]
    G --> I[30 mm for Cables/Large Bars]
    G --> J[Clear Spacing Requirements]
    J --> K[≥ 1/3 Aggregate Size]
    J --> L[≥ 3 × Wire Diameter]

These measures ensure concrete durability and protection of reinforcement.

Testing Requirements for Poles and Brackets as per IS 2193

1. Test Setup (Clause 8.2.1):

• Brackets are tested in their standard orientation at the top of the pole or mounted on a special pole head replicating original dimensions.
• The pole or pole head must be firmly secured in a vertical position.

2. Sampling and Acceptance (Clause 9.1.3 & Table 4):

• Note: Poles or brackets tested up to the first crack stage may be reused if cracks close after unloading.

3. Inspection Parameters (Clause 9.2.1):

• Overall length
• Cross-sectional dimensions
• Uprightness according to Clause 3.2

4. Defect Evaluation:

• Any pole or bracket not meeting dimensional or strength requirements is deemed defective.
• A lot is accepted if the number of defective units does not exceed limits specified in Table 4.

Overview Flowchart

flowchart TD
    A[Select Sample Size (Refer Table 4)] --> B[Check Dimensions and Uprightness]
    B -->|Pass| C[Test for Strength at First Crack and Ultimate Load]
    B -->|Fail| D[Mark as Defective]
    C -->|Pass| E[Accept Pole/Bracket]
    C -->|Fail| D
    D --> F{Defective Count ≤ Acceptance Number?}
    F -->|Yes| G[Accept Lot]
    F -->|No| H[Reject Lot]

This protocol maintains quality control consistent with IS 2193.

Key Points on Sampling and Inspection per IS 2193

1. Load Requirements (Clause 8.2.5)

• Failure load must be greater than or equal to the maximum working load multiplied by the design load factor.

2. Sampling Size and Acceptance Criteria (Clause 9.1.3, Table 4)

• Note: Poles or brackets that sustain first crack testing can be reused if cracks close once loads are removed.

3. Inspection Details (Clause 9.2)

• Number of tests and criteria depend on lot size and previous test outcomes.
• Failure is defined as load capacity below the design load times load factor.

Sampling Flow Diagram

flowchart TD
    A[Start: Lot of Poles or Brackets] --> B{Determine Lot Size}
    B -->|≤ 100| C[Sample 10 Units]
    B -->|101-200| D[Sample 15 Units]
    B -->|201-300| E[Sample 20 Units]
    B -->|301-500| F[Sample 30 Units]
    C --> G[Check Dimensional Defects ≤ 1]
    D --> G
    E --> G
    F --> G
    G --> H{Strength Failures at First Crack ≤ Acceptance Number}
    H -->|No| I[Reject Lot]
    H -->|Yes| J{Ultimate Strength Failures ≤ Acceptance Number}
    J -->|No| K[Reject Lot]
    J -->|Yes| L[Accept Lot]

This ensures quality through controlled defect limits aligned with lot size.

Marking Instructions for Poles as per IS 2193

Clause 10.1: Essential Markings

Poles must be distinctly and permanently marked before testing such that markings remain legible post-installation. Markings should include:

• Month and year of manufacture
• Manufacturer’s name or registered trademark
• Serial or identification number
• Centre of gravity location marked as "C.G."

Clause 10.2: ISI Certification Mark

• Poles may bear the ISI Certification Mark.
• This mark confirms conformity to Indian Standards under ISI's quality assurance and inspection.
• Usage is governed by the Indian Standards Institution (Certification Marks) Act.

Reference Table: Distance from Luminaire Support to Light Source (Clause 5.4, Table 2)

*Distances can vary within the stated ranges.

Sampling & Quality Control (Clause 9.1.3, Table 4)

These marking and sampling standards ensure traceability and adherence to IS 2193.

Details to be Provided with Enquiry or Order as per IS 2193 (Clause 11.1)

When requesting or ordering precast prestressed lighting poles, specify:

• Desired pole mounting height (in meters)
• Type of luminaire (top or side entry) with outreach length
• Weight of the luminaire and any raising/lowering mechanisms

Reference Table: Distance from Luminaire Support to Center of Light Source (Clause 5.4, Table 2)

*Distances vary based on design specifics.

Sampling & Quality Control Requirements (Clause 9.1.3, Table 4)

Additional Information

• Poles may bear the ISI Certification Mark indicating compliance.
• Poles tested up to first crack stage may be reused if cracks close after unloading.

This information facilitates proper specification and adherence to quality per IS 2193.