Steel Pole Analysis and Software Solutions

With experience from 1993 and formed as a separate company in 1996, K2 Engineering, Inc. has specialized in the development of a suite of software-based tools and methods targeted to manufacturers of steel poles and allied equiment, helping them to design and manufacture their products: quicker, lighter in weight, more consistantly, with better documentation, to a variety of applicable codes and standards. Our focus is on helping you automate and streamline your engineering and manufacturing operations as much as possible, freeing your engineers to focus on higher level tasks instead of repetive drudgery, ultimately pushing more and higher-valued product out the door. This all flows to the bottom line where it really counts.

Not sure where to begin? Suspect that you could be doing things better, faster, and more efficiently, but not sure just what is possible? Well, begin by calling or emailing us. The initial consultation is at no cost or obligation to you. Chances are, we'll be able to suggest some course (or courses) of action that you might want to consider, some possibly involving us and some possibly involving third parties. If so, you'll know right away. If we're not the right solution for you, you'll know that right away as well. However, we may be able to refer you to other organizations within our circle of professional contacts which would be a better fit for your needs. (We are quite accustomed to working with third party engineering and manufacturing companies and/or with your in-house personnel). Either way, just the cost of a phone call and a bit of your time.

Finite Element Analysis (FEA) of various steel pole structural components

Most any structual component of a steel pole can be modelled. Just a few possible components are shown above. Some commonly modelled components are: baseplates with or without gussets, framed openings, and arm connections and/or vang plates. Any grade of material can be modelled, if its physical properties are known. Both Static Stress and Eigenvalue (natural frequency and mode shape) analyses are offered. Components can be modelled using corroded or un-corroded thicknesses. Components fabricated from plate are modeled using Plate/Shell elements (where thickness is an input parameter). Bolts are modelled using 3D Beam elements and are joined to adjacent plate elements with Rigid Link elements. Welds are typically assumed to be of a full penetration type and develop the full strength of the joined plates. Optionially, some welds may be modelled using Rigid Link elements, especially when joining thick plates. Boundary conditions at tops and bottoms of tubes feature user-defined translational and rotational stiffnesses. Loads may be applied directly to an element node or to a master node of a 'spider web' of Rigid Link elements joining many nodes. Elements sizes at areas of interest (high stress gradients) are typically 1 inch square or smaller. Element sizes away from areas of interest gradually increase with distance. Most analyses are linear - i.e., do not taken into consideration very large deflections or material yielding. Some more elaborate analyses may consider both geometric and material non-linearities. A variety of stress quantities may be visualized: Von Mises Stress, Principal Stresses, and Maximum Shear Stresses. A variety of deflection quantities may be visualized: X/Y/Z Deflection and Resultant Deflection. Generated reports incude maximum and minimum stresses and deflections and reactions at locations of applied boundary conditions. Generated reports may be customized to your exacting needs. Questions about the intricacies of FEA analysis? Please contact us from some answers!   The initial consutation is free. Here are a couple of links that you might want to look at, regarding FEA. Wikipedia - Finite Element Method What is linear static FEA analysis? How can FEA be useful in your development process? How to get meaningful and correct results from your finite element model (PDF file)

Below are some of the pole-specific software tools which K2 Engineering offers:

(Note: Please call if you have other needs not like anything shown here. K2 Engineering provides customized software solutions.)

PLS-Pole to SolidWorks - a tool to convert PLS-Pole XML-based analysis data into SolidWorks solid models.

The creation of a solid model of an arm bracket. The creation of a solid model of a vang plate. The creation of a solid model of several baseplates. The creation of a solid model of two pole tubes.

Compatible with PLS-Pole Version 8.1 and later. Natively reads PLS-Pole 'postproc'-style XML files. Does NOT require PLS-Pole to be installed. The user's machine must have SolidWorks (Version 2016 or later) installed, however. (All testing was done with SolidWorks 2016.) User-specified SolidWorks Part and Assembly templates (.prtdot and .asmdot files) are used allowing tailoring to user's particular design environment. Note: SolidWorks™ is a trademark and is a licensed product of the Dassault Systemes, Inc. User has option to enter all geometry data by hand, if desired, if a suitable PLS-Pole XML file is not available. All data and settings can be stored and later retrieved from an industry-standard XML-based data file. Tubes having 1 or 2 seams are supported. Locations of seams relative to Longitudinal direction are configurable. Tube pieces (traps) are created from user-specified input including: starting and ending width, wall thickness, axial length, etc. Locations of flats and points relative to seams are configurable. Each tube piece is "mated" to adjoining pieces to create a tube assembly. For Tube assemblies, output consists of a Part (.SLDPRT) document for each piece and an Assembly (.SLDASM) Document for each tube assembly. For Tube Assemblies, input and output file names and locations are configurable. Up to 10 round holes (of any diameter that will fit on the flat) per tube are supported and configurable and may be on any flat. Up to 8 different configurations of flanges and baseplates are supported with a wide variety of outer shapes. For baseplates, quadrant spacing (or equal spacing) of bolt holes is as per the user input for both 1 and 2 bolt circles. For flanges and baseplates, a wide variety of center holes shapes and drain hole schemes are supported. Up to 8 different configurations of Arm Brackets are supported, each with up to 10 user-configured holes. Up to 8 different configurations of Arm Vangs are supported, each with up to 10 user-configured holes. In a multi-pole structure, if importing from PLS-POLE, the desired pole may be selected from a pop-up menu. Note: As it exists now, this program is a Proof-of-Concept to demonstrate how SolidWorks files may be created on-the-fly. Note: K2 Engineering will modify/customize/extend the program and it's output to meet your exacting needs.

K2Pole - Pole Analysis via: AASHTO LTS-6 and LRFD-1, EN 40, BS 5649, and ILP PLG 07 (2013)

Support for: AASHTO LTS-6 and LRFD-1, EN 40, BS 5649, and ILP PLG 07 (2013). Support for: CSA S6 and ILE TR7 is contemplated as future development. Support for 8, 12, 16, 18, 20, 24, and 36 sided poles as well as Round (where Design Code permits). All standard thicknesses (including gaged) are available in a drop-down box along with an override method for non-standard thicknesses, or metric equivalents. Analysis handled by embedded Finite Element Analysis (FEA) module. P-Delta analysis is available in some load case configurations. Non-linear static stress analysis is available in some load case configurations. Mode 1 - 4 mode shapes and frequencies are calculated using an FEA Eigenvalue analysis. Support for embedded poles (fixity assumed at a user-specified distance below grade). Support for up to 8 Davit Arms, each with up to 5 appurtenances. Support for up to 4 un-reinforced or reinforced openings (Generally as per definitions in EN 40). Support for up to 10 user-defined material property set definitions. Support for accounting of mass of internal cabling (if any). Support for both Metric and British unit sets, both input and output. Support for fatigue analysis (as per Design codes). Support for wind loads from the 8 cardinal directions. Wind load combinations are also supported. Some limited support for seismic equivalent lateral loading. Response Spectrum analysis is currently under development. Pole geometry can be inferred or directly input. Multiple methodologies for specifying/determining lap lengths. Up to 5 point loads can be defined using Equivalent Projected Area and wind parameters or directly specified at any height in any direction. A top mounted appurtenance can be defined. Assumed to be mounted concentric with the pole axis but facing at any azimuth. The wind loads on step bolts may optionially be modeled. All parameters describing head assembly and luminaires at the top of the pole are user specifiable. All significant results parameters (moments, stresses, shears, etc.) can be plotted versus height. All input data and all calculated results are printed out in a nicely formatted manner. Calculated loading parameters (such as drag coefficient) for each pole or arm segment, or appurtenance or point load, may optionially be output in table form. WYSIWYG (What You see Is What You Get) on-screen preview is supported for all printed and plotted output. For ease of use, optionially 'remembers' user settings and configurations from previous sessions. All input data and analysis settings are stored in industry standard, non-proprietary XML format data files. Voluminous text and graphics output capabilities - all user configurable. Support for simplified 3D rendering of pole. (Requires that OpenGL be installed). Text and graphics output may be 'branded' with your company logo and complete contact information. Note: K2 Engineering can modify the program and it's output to meet your exacting needs. Click here to view sample text output of an AASHTO LTS-6 analysis of a pole with davit arms. (British PDF format) Click here to view sample graphics output of an AASHTO LTS-6 analysis of a simple pole. (British PDF format) Click here to view sample text output of an EN 40 analysis of a pole with an opening. (Metric PDF format) Click here to view screen shots of the program in action. (PDF format) Click here to view the Help file for program K2Pole. (PDF format)

PLS-Pole to Inventor - a tool to convert PLS-Pole XML-based analysis data into an AutoDesk Inventor 3D model.

A round hole being placed in a desired flat. Three tubes for a pole imported from PLS-Pole. Two possible configurations of a baseplate. Tube piece (trap) unfolded into flat pattern.

Compatible with PLS-Pole Version 8.1 and later. Natively reads PLS-Pole 'postproc'-style XML files. Does NOT require PLS-Pole to be installed. The user's machine must have AutoDesk Inventor (version 2010 or later) installed, however. Note: AutoDesk™ and Inventor™ are trademarks and licensed products of the AutoDesk Corporation. User has option to enter all geometry data by hand, if desired, if a suitable PLS-Pole XML file is not available. Tubes having 1, 2, 3, or 4 seams are supported. Locations of seams relative to Longitudinal direction are configurable. Tube pieces (traps) are created from a user-customizable part template with custom material properties, bend "K" factor, etc. Flat patterns are automatically computed and included inside each part file. Locations of flats and points relative to seams are configurable. Each tube piece is "mated" to adjoining pieces to create a tube assembly. Output consists of a Part (.IPT) document for each piece and an Assembly (.IAM) Document for each tube assembly. Input and output file names and locations are configurable. Up to 10 round holes (of any diameter that will fit on the flat) per tube are supported and configurable and may be on any flat. Both round and square baseplates (with optional corner clips) are supported. Quadrant spacing of bolt holes is as per the definition inside PLS-Pole. PLS-Pole bolt hole definition may be overridden by user, if desired. PLS-Pole files in metric units are supported. (Output Inventor models will be in British units, however.) Up to 12 poles are supported in each structure, with a maximum of 8 tubes per pole. In a multi-pole structure, the desired pole may be selected from a pop-up menu. Note: As it exists now, this program is a Proof-of-Concept to demonstrate how Inventor files may be created on-the-fly. Note: K2 Engineering will modify/customize/extend the program and it's output to meet your exacting needs. Click here to view sample screen shots of the program in action. (PDF format) Click here to view sample screen shots of Inventor displaying the results. (1 of 2) (PDF format) Click here to view sample screen shots of Inventor displaying the results. (2 of 2) (PDF format) Click here to view a short video of the program in action creating a pole 3D model. Click here to view a short video of the program in action creating a baseplate 3D model. Note: These videos are in .AVI format and will require Windows Media Player or a similar program to view them. Note: Video with a higher resolution and frame rate is available upon request.

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PLS-Pole to MathCAD - a tool to convert PLS-Pole XML-based analysis data into a MathCAD spreadsheet format.

Compatible with PLS-Pole Version 8.1 and later. Natively reads PLS-Pole 'postproc' XML files. Does NOT require PLS-Pole to be installed. The user's machine must have MathCAD (version 14 or later) installed, however. The destination MathCAD file can be created from scratch or the data can be written into an existing spreadsheet file. The user points to the desired .XMCD files via a standard file selection dialog. PLS-Pole files in metric units are supported. (Output MathCAD files will be in British units, however.) Up to 12 poles are supported in each structure, with a maximum of 8 tubes per pole. Up to 100 distinct load cases are supported. Up to 200 joints are supported. Up to 20 tubular davit arms are supported. Up to 100 tubular cross arms are supported. Up to 50 attachments per pole are supported. Note: As it exists now, this program is a Proof-of-Concept to demonstrate how MathCAD files may be created on-the-fly. Note: K2 Engineering can modify/customize/extend the program and it's output to meet your exacting needs. Note: K2 Engineering can develop customized MathCAD formulas and functions to integrate this tool with your other MathCAD-based solutions or with other analysis packages beside PLS-Pole. Please call to discuss your requirements. Note: The example shown below is a rather simple demo which automates the transfer of data from a PLS-Pole results XML file into the 'High Mast Lighting' spreadsheet developed by the Florida Department of Transportation (DOT) for the analysis of light standards. K2 Engineering can greatly customize and extend this program to transfer data from PLS-Pole to your suite of in-house MathCAD spreadsheets, formatted exactly as you specify. Click here to view a sample PLS-Pole Analysis Results file (XML file) used to create this demo. Click here to view screen shots of the progam in action. Note: to view the MathCAD .XMCD files below, click on the "here" link to cause the .XMCD file to be shown in text mode. Using your browser's "Save Page As" options, save the page as a text (.TXT) file on your hard drive and then rename the extension of the saved file from .TXT to .XMCD. Then, open the .XMCD file with MathCAD (version 14 or later). XMCD is MathCAD's new XML-based open-source file structure. Click here to view the original FLA DOT spreadsheet. Click here to view the new spreadsheet with modified data. Click here to view the original FLA DOT spreadsheet (in PDF format). Click here to view the new spreadsheet with modified data (in PDF format). A number of pole-related MathCAD spreadsheets are freely available at the Florida DOT Structures Design Office page. More information about MathCAD, along with purchasing information, can be found at the PTC MathCAD page. PTC (Parametric Technologies) is the new owner of MathCAD.




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Bolted Plate - a tool to analyze and/or design flange plates, base plates, and davit arms / pole vangs

Compatible with PLS-Pole Version 8.1 and later. Natively reads PLS-Pole 'postproc' XML files. Does NOT require PLS-Pole to be installed. Supports ASCE 48-05, ASCE 48-11, ASCE 48-19, TIA/EIA 222-G, AISC ASD, and AASHTO LTS-6 design codes. Support for user-mandated values,settings, and configurations. Operates in either 'check-only' or 'automatic re-design' mode. Support for both Metric and British unit sets, both input and output. Support for both Metric and British unit-denominated materials and bolts, via drop-down menus. Support for user-configurable lists of materials and bolts, both in Metric and British units. Can handle davit arms / pole vangs, flange joints and baseplates w/ anchor bolts. Where possible, input is via drop-down boxes and check boxes to minimize typing and input errors. Support for up to 100 load cases, each with: Load Factor, Strength Reduction Factor, and Allowable Stress Increase Factor. Support for specifying loads as a percentage of capacity of adjacent tube. Support for a wide variety of pole geometries, plate and hole shapes, bolt coordinates, etc. Multiple methods for specifying effective lengths of bend lines. Checks all possible bend lines (for both pole points and pole flats) for every load case. For ease of use, optionially 'remembers' user settings and configurations from previous sessions. Data is stored in industry standard, non-proprietary XML format. Voluminous text and graphics output capabilities - all user configurable. Output of DXF file suitable for subsequent CNC operations, i.e., "part burning". Click here for a sample text output, for baseplates, with all options active. (PDF file) Click here for a sample text output, for baseplates, in a simplified format. (PDF file) Click here for a sample text output, for davit arms, with all options active. (PDF file) Click here for a sample text output, for davit arms, in a simplified format. (PDF file) Click here for a set of screen shots, showing all input screens. (PDF file) Click here for an example of graphics output, for baseplates, with all graphics options enabled. (PDF file) Click here for an example of graphics output, for baseplates, with only some options enabled. (PDF file) Click here for an example of graphics output, for davit arms, with all graphics options enabled. (PDF file) Click here to view the Help file for program BoltedPlate.(PDF file) Click here to view Example 1 of DXF output suitable for CNC operations (JPG file) Click here to view Example 2 of DXF output suitable for CNC operations (JPG file) Click here to view Example 3 of DXF output suitable for CNC operations (JPG file) Note: K2 Engineering can modify the program and it's output to meet your exacting needs.

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PLS-Pole to Word - a tool to create a text summary of a pole analysis in Microsoft Word, from PLS-Pole analysis data.

Compatible with PLS-Pole Version 8.1 and later. Natively reads PLS-Pole 'postproc' XML files. Does NOT require PLS-Pole to be installed. Directly creates a Microsoft Word .DOC file using any version of Word from Word 97 to Word 2010. Word must be installed. Can be configured as a post-processor to PLS-Pole or run as a stand-alone program. Intended to convey design intent to third parties (end customer, erection contractor, permitting authorities). Tables include information about both the pole and it's appurtenances (arms), as well as loadings, etc. Formatted to be easy to read and understand and stripped of non-essential information. Optionially can produce PDF files directly, if using Word 2010 and Adobe Acrobat 8.0 or later. Style and format of document, including company logo, is totally customizable by end user. Click here for a better view of the example text summary shown to the left. (PDF file) Click here for a better view of the example text summary shown to the left. (DOC file) Note: As it exists now, this program is a Proof-of-Concept to demonstrate how MS-WORD files may be created on-the-fly. Note: K2 Engineering can modify the program and it's output to meet your exacting needs.

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Tube Flat Pattern - a tool to create DXF files of tubular flat pattern layouts.

Compatible with PLS-Pole Version 8.1 and later. Natively reads PLS-Pole 'postproc' XML files. Does NOT require PLS-Pole to be installed. If not using PLS-Pole, geometry data can be read from a data file, or typed in. PLS-Pole files in metric units are supported. (Output DXF files will be in British units, however.) DXF files are suitable for input into a nesting program, such as ProNest. Support for ProNest .PLN configuration files. Output DXF files are based upon a supplied DXF template file, which is completely user-customizable. Does NOT require AutoCAD or nesting program to be installed. Edge bevelling of tube long side and ends is supported if target CNC machine has this capability. Bevelling angles for sides and ends can be individually specified. Etching of part numbers, bend lines, flat numbers, etc. is supported if machine has this capability. Support for "nipple" style bendline indicators is provided, if desired, and is operator configurable. (Etching shown as Cyan color in example to left). Etching for part numbers, etc. is on a different layer than etching for bend line indicators. 'Stitch outlining' of large holes (such as handholes) is supported (to minimize warping during bending). Holes may be centered on either a bendline or a flat and may have a centerline offset referenced from either end. Support for 1, 2, 3, or 4 long seams is supported. Output of echo of input design data to a non-burn (ignored) layer is supported. (Grey text regions at left) Output of design data to a .TXT file in either verbose or simplified mode is supported. Support for 'mathematically unfolding' developed parts, such as trapezoids (traps) for tube-like shapes. Support for pole tubes, davit arms, and cross arms, whether faceted or round. Support for mitering of both ends of tube, about one or both axes. Support for optional run-on/run-off tabs. Support for optional output to PDF files (Requires a version of AutoCAD to be present). Option for input of tube widths in either flat/flat or point/point dimensions. Multi-pole structures are supported (on a pole-by-pole basis). User may select which pole tubes, davit arms, or cross arms are to be processed from a menu. Support for user-customizable "layout rules" to specify number, orientation and location of long seams, based upon tube geometry. Layout Rules are stored in XML files. An unlimited number of Layout Rules files may be defined. Click here for a set of screen shots, showing all input screens. (PDF file) Click here for a sample XML-based data file for a sample job. (XML file) Click here for a sample XML-based "layout rules" file, which is user-customizable. (XML file) Note: to view the DXF files below, click on the "here" link to cause the DXF file to be shown in text mode. Using your browser's "Save Page As" options, save the page as a text (.TXT) file on your hard drive and then rename the extension of the saved file from .TXT to .DXF. Then, open the .DXF file with AutoCAD or another tool which can read DXF files. Click here for a sample DXF output file (Piece 1 of 2 pieces in a 2-seam tube # 1) (DXF file) Click here for a sample TXT output file (Piece 1 of 2 pieces in a 2-seam tube # 1) (DXF file) Note: As it exists now, this program is a Proof-of-Concept to demonstrate how flat pattern DXF files may be created on-the-fly. Note: K2 Engineering can modify the program and it's output to meet your exacting needs.

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DWG Generator - a tool to create native AutoCAD DWG files on-the-fly.

Directly creates a to-scale, dimensioned AutoCAD drawing (in .DWG format) (anchor bolt cage, shown as example). The drawing is intended to convey design intent. In this example,for anchor bolt cage fabrication. The drawing contains an automatically generated Bill of Materials (BOM). Compatible with PLS-Pole Version 8.1 and later. Natively reads PLS-Pole 'postproc' XML files. Does NOT require PLS-Pole to be installed. If not using PLS-Pole, geometry and configuration data can be read from a data file, or typed in. PLS-Pole files in metric units are supported. (Output drawings will be in British units, however.) Can be configured as a post-processor to PLS-Pole or run as a stand-alone program. Requires the presence of some recent version of the full AutoCAD (not AutoCAD LT). The end user may supply a customized border template DWG file with their own logo, border, color scheme, etc. The program invokes and remotely controls AutoCAD while running it in the background. Once properly configured, the program can be used by personnel without need of any AutoCAD experience. For ease of use, optionially 'remembers' user settings and configurations from previous sessions. Click here for a better view of the first example drawing shown to the left. (PDF file) Click here for a better view of the second example drawing shown to the left. (PDF file) Note: As it exists now, this program is a Proof-of-Concept to demonstrate how native AutoCAD DWG files may be created on-the-fly. Note: The program can be extended and modified as needed to depict other aspects of the pole configuration. Note: K2 Engineering can modify the program and it's output to meet your exacting needs.

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Pole DXF - a tool to create DXF files on-the-fly.

Directly creates a to-scale, dimensioned AutoCAD drawing (in .DXF format) (pole sketch, shown as example). The drawing is intended to convey design intent. In this example,a pole imported from a PLS-Pole XML file. The drawing contains several tables, populated from data from the PLS-Pole file. Compatible with PLS-Pole Version 8.1 and later. Natively reads PLS-Pole 'postproc' XML files. Does NOT require PLS-Pole to be installed. PLS-Pole files in metric units are supported. (Output drawings will be in British units, however.) Can be configured as a post-processor to PLS-Pole or run as a stand-alone program. Does not require the presence of any version of AutoCAD. The end user may customize the supplied border template DXF file with their own logo, border, color scheme, etc. The end user may customize layer names and layer colors, location of elevation view, etc. as desired. Dates, initials, company name and logo. title block info, etc. may be customized by the end user. Once properly configured, the program can be used by personnel without need of any AutoCAD experience. For ease of use, optionially 'remembers' user settings and configurations from previous sessions. Click here for a better view of the example drawing shown to the left. (PDF file) Note: As it exists now, this program is a Proof-of-Concept to demonstrate how native DXF files may be created on-the-fly. Note: The program can be extended and modified as needed to depict other aspects of the pole configuration. Note: K2 Engineering can modify the program and it's output to meet your exacting needs.

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PLS-Pole to Excel - a tool to convert PLS-Pole XML-based analysis data into an Excel spreadsheet format.

Compatible with PLS-Pole Version 8.1 and later. Natively reads PLS-Pole 'postproc' XML files. Does NOT require PLS-Pole to be installed. The user's machine must have Microsoft Excel (version 2007 or later) installed, however. The destination Excel file can be created from scratch or the data can be written into an existing spreadsheet file. The user points to the desired .XML and .XLSX files via a standard file selection dialog. PLS-Pole files in metric units are supported. (Output Excel files will be in British units, however.) Each line in a given table is assigned a unique variable name (for example, SteelPoleData001) to allow user-written macros to easily reference the desired pieces of data. Up to 12 poles are supported in each structure, with a maximum of 8 tubes per pole. Up to 100 distinct load cases are supported. Up to 200 joints are supported. Up to 20 tubular davit arms are supported. Up to 100 tubular cross arms are supported. Up to 50 attachments per pole are supported. Note: As it exists now, this program is a Proof-of-Concept to demonstrate how Excel files may be created on-the-fly. Note: K2 Engineering can modify/customize/extend the program and it's output to meet your exacting needs. Note: K2 Engineering can develop customized Excel macros to integrate this tool with your other spreadsheet-based solutions. Click here to view a sample PLS-Pole Analysis Results file. (XML file) Click here to view the Excel (.XLSX) file made from the above sample PLS-Pole XML file.




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