High Mast Lighting & Structural Pole Products
Pre-engineered configurations ready for international municipal and mega-infrastructure tender bidding, supported by structural safety documentation and DIALux photometric design.
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View ProductHigh Mast Illumination Dynamics & Structural Safety Criteria
Comprehensive engineering criteria for high-elevation luminaires operating between 15 meters and 45 meters, subjected to aerodynamic drag, vortex-induced vibrations, and severe micro-climates.
Structural Alloy & Wind Resistance
Fabricated using prime hot-rolled Q355B (equivalent to ASTM A572 Grade 50 and EN S355JR) structural steel. Each polygonal section (12, 16, or 20-sided) is optimized via Finite Element Analysis (FEA) to endure hurricane-level gusts up to 160 km/h (45 m/s) with a minimum 2.5x structural factor of safety per AASHTO LTS-6 standard.
High-Flux Photometric Precision
Delivering systemic luminous efficacy exceeding 160 lm/W to 180 lm/W through premium Lumileds or Cree SMD5050 LED arrays. Optical grade polymethyl methacrylate (PMMA) multi-pattern lenses ensure precise asymmetric distribution (Type II, III, IV, or V), eliminating light trespass and suppressing sky-glow per dark-sky ordinances.
ASTM A123 Hot-Dip Galvanization
Total immersion galvanization in a 450°C molten zinc bath produces a multi-layered iron-zinc alloy coating with a certified minimum thickness of 86 μm to 100 μm. Paired with optional thermoset electrostatically applied polyester powder coating (RAL colors), the system guarantees 30+ years of maintenance-free service life in ISO 12944 C5-M coastal marine atmospheres.
Unrivaled Supply Chain Vertical Integration
Why Yangzhou Xintong Traffic Equipment Group delivers institutional EPC projects on tighter schedules, with superior metallurgic control and lower total landed cost.
16-Meter CNC Tandem Press Brakes
Equipped with twin synchronized 1,200-ton CNC bending machines capable of forming seamless octagonal, 12-sided, and 20-sided mast sections up to 16 meters in a single pass, eliminating transverse weak points.
Submerged Arc Automatic Welding (SAW)
Longitudinal automatic submerged-arc welding machines with online ultrasonic flaw detection ensure penetration over 90% without undercut or porous air pockets, certified to AWS D1.1 and EN ISO 15614 structural codes.
In-House Galvanizing & Electrostatic Line
Direct ownership of hot-dip galvanizing kettles and German GEMA electrostatic powder-coating lines allows zero third-party transport delays, stringent zinc bath chemical monitoring, and unified quality traceability.
SMT Cleanroom & Burn-in Testing
High-speed surface-mount assembly of luminaire boards with conformal anti-corrosion silicone coating, paired with 100% 72-hour full-load thermal burn-in testing to guarantee zero infant mortality before sea dispatch.
Global EPC Specification & Mechanical Standards
Comprehensive engineering matrix reconciling AASHTO, European EN, and international maritime specifications for multi-megawatt outdoor high-mast tenders.
| Engineering Parameter | Highway & Transit Hubs | Container Terminals & Seaports | International Airport Aprons | Sports & Athletics Arenas |
|---|---|---|---|---|
| Mounting Height (Meters) | 15 m – 25 m | 25 m – 35 m | 25 m – 40 m | 20 m – 45 m |
| Mast Geometry & Steel | Octagonal / 12-sided Q355B | 16-sided / 20-sided Q355B | 16-sided / 20-sided Q355B | Polygonal Cross-arm / Structural Steel |
| Lowering System (Lifting Mechanism) | Internal dual-drum winch / Motorized | Self-latching docking head / SUS316 cables | Fixed platform with ladder cage or winch | Fixed service platform with safety rail |
| Total Luminaire Power (Watts) | 1,200 W – 3,600 W (4–8 fixtures) | 2,400 W – 8,000 W (6–16 fixtures) | 3,000 W – 9,600 W (Low Glare Asym.) | 4,000 W – 20,000 W (High TLCI >85) |
| Optics & Glare Control | Cut-off Asymmetric (IES Type II/III) | Forward-throw 60°×120° / Anti-corrosion | FAA/ICAO Annex 14 compliant cutoff | Narrow/Medium 15°–45° for TV broadcast |
| Surge Protection & Driver | 10 kV / 20 kV SPD, Mean Well / Inventronics | 20 kV SPD with salt-spray IP67 barrier | 20 kV Class I SPD, THD < 10%, PF > 0.98 | Remote driver cabinet with flicker < 1% |
| Design Wind Load Velocity | 130 – 150 km/h | 160 – 180 km/h (Typhoon Grade) | 150 – 160 km/h | 140 – 160 km/h |
Localized Application Scenarios & Field Realities
How Xintong custom-calibrates high mast structures and LED optical engines to the unique environmental stresses of global industrial facilities.
Maritime Ports & Container Terminals
Container logistics demand wide-beam vertical illuminance to read container ISO codes stacked 6-high without casting blind shadows in gantry aisles. Our port-series masts incorporate 316 stainless-steel pulleys and C5-M marine multi-coat barrier systems resistant to saline fog, sulfurous ship exhaust, and constant wind shear.
Aviation Aprons & Taxiways
Airport apron aprons operate under strict ICAO Annex 14 and FAA Aerodrome Design requirements: zero upward light emission (U0 rating) to avoid blinding cockpit pilots and air traffic controllers. We configure custom sharp-cutoff visor shields and twin-circuit aviation obstacle beacons with integrated photodiode auto-switching.
High-Speed Highway Interchanges & Toll Gates
Complex multi-level elevated flyovers require uniform broad-area coverage with strict luminance uniformity ratios (Uo ≥ 0.40, Ul ≥ 0.70 per CIE 115). High mast installations drastically minimize roadside obstacles compared to dozens of conventional poles, substantially improving vehicle crash safety.
Next-Generation High Mast Infrastructure Trends
The convergence of advanced semiconductor thermodynamics, IoT edge computing, and predictive structural health monitoring.
Driver Efficacy Exceeding 180 lm/W
Transition from traditional metal halide (65 lm/W) and early generation LEDs to micro-groove extruded copper heat-pipes with pure aluminum fin arrays. Operating junction temperatures stay below 65°C under 45°C ambient heat, guaranteeing L90B10 lifespans beyond 100,000 continuous hours.
IoT LoRaWAN & DALI-2 Centralized Control
High masts now function as smart connectivity nodes. Through LoRaWAN or cellular NB-IoT micro-controllers, facilities operators remotely schedule dynamic stepped dimming, monitor real-time harmonic distortion, track power consumption, and receive predictive maintenance alerts on failed driver channels.
MEMS Dynamic Vibration Dampers
Tall flexible structures are susceptible to second-mode vortex shedding oscillations at moderate wind speeds. Modern Xintong high masts integrate internal mechanical pendulum dampening or top-mounted helical strakes to prevent structural fatigue along longitudinal weld lines.
Frequently Asked Technical & Commercial Questions
Direct engineering responses to key specification issues faced by international EPC contractors, consulting engineers, and port authorities.
What mechanical safety locks are utilized on motorized raising-and-lowering high mast systems?
Xintong motorized high mast systems utilize a positive mechanical self-latching head assembly. When the luminaire carriage reaches its maximum operating elevation, two heavy-duty zinc-nickel plated steel latching hooks automatically engage into the structural docking pins on the top mast head. This mechanical transfer completely removes tension from the stainless steel hoisting wire cables (SUS304/SUS316) during operation, ensuring that cables are not left under continuous load, eliminating cable fatigue, stretching, and accidental drop risk under severe high-wind vibrations.
How does Xintong compute and verify foundation anchor bolt stresses under AASHTO wind-loading?
Our in-house structural engineering department performs finite element stress calculations taking into account project-specific design wind velocity, gust response factors, terrain roughness classification (Exposure B, C, or D), luminaire effective projected area (EPA), and soil bearing capacity. Anchor cages are fabricated using high-tensile 8.8 grade or 10.9 grade galvanized steel studs. Along with the structural delivery, we supply certified foundation depth, rebar reinforcement cages, and bolt torque tables signed by qualified structural engineers for tender submittal.
How are LED high mast drivers protected against destructive electrical surges and lightning strikes?
All Xintong LED high mast luminaires incorporate two-stage transient voltage surge suppression (TVSS). An initial primary 10 kV/20 kV Class I/II surge protective device (SPD) is installed inside the luminaire gear box, complemented by a secondary centralized 20 kA to 40 kA SPD in the bottom base-door distribution panel. Lightning strike energy is dissipated directly into the foundation earth ground ring via a solid copper air terminal attached to the very apex of the high mast pole, maintaining mast ground resistance below 5 Ohms.
Can you provide DIALux simulations to confirm airport apron ICAO Annex 14 compliance?
Yes. Our certified lighting simulation team produces turnkey DIALux and DIALux evo calculation packages. We import your AutoCAD aerodrome layout, map apron parking positions, and simulate 3D horizontal and vertical illuminance grids, aiming angles, uniformity coefficients (Emin/Eavg), and Unified Glare Ratings (UGR). Calculations prove compliance with ICAO Annex 14 (30 lux average apron, 0.40 minimum uniformity, UGR < 50) and FAA AC 150/5360-13 guidelines prior to manufacturing release.
What is the standard container loading protocol for 25m to 40m polygonal sectional shafts?
High masts over 12 meters are manufactured in slip-joint conical/polygonal sections engineered to telescope into standard 40-foot High Cube (40HQ) maritime shipping containers. Each telescoping joint is designed with a standard overlap length of 1.5 times the mating section's internal diameter. Mast sections are wrapped with protective geotextile strapping, heavy bubble wrap, and non-marking rubber spacers to prevent zinc abrasion during ocean transit, drastically decreasing international freight expenditure.
High Mast & Infrastructure Support Line
Explore our complete production line of certified high mast towers, smart street poles, and power transmission shafts built to international standards.
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View ProductSubmittal Data Pack Deliverables For Qualified EPC Tenders
Within 24 to 48 hours of receiving your project bill of quantities (BOQ) or lighting specification schedule, our senior engineering office provides:
DIALux Photometric Studies
Comprehensive 3D false-color isolux diagrams, average lux levels, luminance uniformity ratios, and luminaire schedule ensuring 100% compliance with tender standards.
AutoCAD Structural Drawings
Detailed dimensional shop drawings showing mast tapering, wall thicknesses, slip-joint overlap dimensions, base plate gussets, and anchor bolt cage blueprints.
Certified Mill & Zinc Reports
Q235B / Q355B mill test certificates (EN 10204 3.1) and hot-dip galvanizing magnetic thickness verification reports per ASTM A123 / ISO 1461 requirements.