Project G922 - Custom Steel Lighting Poles for EU Municipal Infrastructure

Custom Steel Lighting Poles for EU Municipal Infrastructure - Project Overview

Project Code: G922Product: Custom-designed steel lighting polesApplication: Urban public lighting infrastructureScope: Engineering validation, dimensional control, production supervision, electrical safety verification, and pre-shipment inspectionMarket: EU public / municipal projects

Project G922 involved the manufacturing and on-site validation of custom steel lighting poles intended for long-term urban deployment. The project required strict alignment between approved engineering drawings, real production output, and installation realities in public infrastructure environments.

SHAMANA was engaged to provide on-site engineering control, ensuring that what was designed was exactly what was manufactured, tested, and shipped.

Technical Specifications

(Validated Physically on Site)

All critical dimensions were measured directly on the production floor and cross-checked against approved technical drawings.

• Total pole height: approx. 8,036 mm

• Base flange: 400 × 400 mm

• Flange thickness: approx. 16 mm

• Pole structure: Tapered steel body

• Service access: Integrated access door for wiring and maintenance

• Surface treatment: Industrial outdoor coating, uniform and defect-free

Dimensional verification was not theoretical. Measurements were taken directly on the steel components prior to packaging.

Approved engineering drawing showing overall geometry and dimensions of the lighting pole.

Quality Control & Inspection Process

SHAMANA conducted a full structural and dimensional inspection, including:

• Base flange dimensions and bolt-hole positioning

• Verticality and straightness of the pole body

• Thickness verification of load-bearing elements

• Service door positioning and internal clearance

• Weld quality inspection (base plate, arm joints, structural seams)

• Packaging method and container loading verification

All inspections were documented photographically and validated directly on site, not via supplier self-declaration.

Total pole length verified on the production floor against approved drawings.

Inspection report project G922 - proof

project-g922-quality-inspection-report-steel-poles.pdf

Download PDF • 4.33MB

Functional test

Project G922 verified on the production floor against - functional test.

Engineering Corrections Applied Before Mass Production

Issue Identified

During inspection, SHAMANA identified a critical structural deviation:

• The curved arm terminal length was insufficient for safe welding and long-term mechanical reliability.

• While visually acceptable, the shortened end reduced weld penetration area and compromised stress distribution under load.

This was a structural risk, not a cosmetic issue.

Engineering correction applied by extending curved arm length to improve weld integrity.

Engineering deviation identified: curved arm end length insufficient for safe welding.

Engineering deviation identified: curved arm end length insufficient for safe welding.

Corrective Action

• Engineering correction of +30 mm minimum added to the curved arm terminal.

• Updated technical drawing issued and validated before series production.

This modification significantly improved:

• weld integrity

• load behavior under wind and vibration

• long-term fatigue resistance

The correction prevented a hidden failure risk that would not have been visible after installation.

Electrical Safety & Compliance Verification

Beyond mechanical validation, the project included electrical safety testing aligned with EU requirements.

HI-POT (Dielectric Withstand) Testing

• Individual high-voltage insulation testing performed on the electrical system.

• Test conditions aligned with LVD (2014/35/EU) safety requirements.

• Verification of insulation integrity between live parts, secondary circuits, and accessible metal structures.

This confirms that electrical safety was physically tested, not assumed.

High-voltage (Hi-Pot) electrical safety test conducted on-site to verify insulation integrity.

CE / EMC / LVD Documentation

The project is supported by:

• CE EMC Test Reports

• Verification of Compliance

• EU Declaration of Conformity

• Component-level certifications (including driver documentation)

Documentation and on-site testing are consistent and mutually reinforcing: what is declared is what was tested.

Electrical compliance verification for lighting pole assemblies

Electrical compliance verification for lighting pole assemblies

Electrical compliance verification for lighting pole assemblies

Electrical compliance verification for lighting pole assemblies

Electrical compliance verification for lighting pole assemblies

Electrical compliance verification for lighting pole assemblies

CE compliance documentation for EU municipal lighting applications

Verified material inspection certificate for structural steel used in Project G922

Manufacturing & Finish Assessment

• Welds: Clean, continuous, no visible porosity or thermal deformation

• Surface coating: Uniform, no bubbling, peeling, or contamination

• Cut-outs & openings: Clean edges, controlled tolerances

• Overall execution: Suitable for municipal-grade infrastructure with long service life expectations

Manufacturing stage showing tapered pole bodies before final finishing.

Manufacturing stage showing tapered pole bodies before final finishing.

On-site inspection of pole bodies to verify straightness and surface quality.

On-site inspection of pole bodies to verify straightness and surface quality.

On-site inspection of pole bodies to verify straightness and surface quality.

Packaging & Logistics Control

• Poles individually protected against abrasion and impact

• Packaging designed to maintain straightness during transport

• Container loading optimized for stability and space efficiency

• No deformation or surface damage observed during packing

Individual pole protection to prevent surface damage during transport.

Controlled container loading process to ensure transport stability.

Final loading inspection confirming correct positioning and protection.

Project traceability and on-site presence by SHAMANA during shipment preparation.

SHAMANA Verdict

✔️ Product execution: Good✔️ Manufacturing quality: Consistent✔️ Engineering control: Critical and effective✔️ Risk mitigation: Successfully applied before mass production

Project G922 demonstrates how on-site engineering verification prevents structural and safety risks that are commonly missed in document-only or remote sourcing models.

Implementation proof

Project G922 traceability during implementation at destination.

What This Case Proves

• Real sourcing is not about drawings. It is about what gets welded, measured, tested, and shipped.

• Small dimensional deviations can generate major downstream risks in public infrastructure.

• Engineering presence on the ground changes outcomes, not just reports.

This project demonstrates how custom steel lighting poles for EU municipal infrastructure require on-site engineering validation, dimensional control, and electrical safety testing to eliminate structural and compliance risks before mass production.

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