Inside a Pole Base: Conduit, Rebar, and Anchor Bolts

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By taking the time to understand the three key interior components in a Pole Base: conduit, rebar, and anchor bolts, you’re laying the groundwork to produce Pole Base with confidence. Each component plays a critical role, and though we’ve made producing Pole Base a simple process, you’ll still need an insider’s view to get up and running fast.

Conduit

Proper conduit placement is essential for electricians running wiring and ensuring reliable access to power. In most cases, conduit runs through the center of the base, but exact placement, depth, and diameter are determined by the project’s electrical site plans.

Conduit specifications are site-specific and typically provided by the electrical engineer or site lighting contractor. These requirements vary depending on factors like:

• Light fixture size
• Power supply
• Number of circuits
• Other electrical demands

Usually made from durable PVC, the conduit protects and routes wiring from the power source to the light fixture, ensuring everything is safely enclosed and code-compliant. Conduit typically comes with a coupler cast into each Pole Base for easy plumbing in the field.

To hold conduit in place during the Pole Base manufacturing process, we’ve engineered conduit magnets that attach to the conduit and the interior sides of the Pole Base form, ensuring a secure placement with every pour.

Rebar

Each Pole Base is reinforced with a custom-fit rebar cage designed to match its size and withstand wind loads and other structural stresses. The cage consists of vertical bolts and round hoops that strengthen the concrete and evenly distribute stress, helping prevent cracks and maintain the base’s integrity over time.

The rebar size and layout are typically specified by a structural or electrical engineer, based on key factors like:

• Light pole height
• Wind load requirements
• Weight of the light pole and light fixture

Rebar is arranged in a grid pattern, with vertical bolts and horizontal round hoops intersecting inside the form. Using a precision rebar jig, Pole Base manufacturers can construct cages for 18, 24, and 30-in (457, 610, and 762 mm) light pole bases with consistency and accuracy.

Anchor Bolts

Anchor bolts are cast directly into the Pole Base and extend from the top of the foundation. These bolts secure the bolt circle and anchor plate, holding the light pole and fixture in place.

Bolt depth, placement, and bolt circle or anchor plate layouts are determined by the specific light pole and the template provided by the light pole manufacturer.

Several factors influence final anchor bolt configuration, including:

• Light pole height
• Wind load requirements
• Anchor plate thickness
• Bolt size and diameter

It’s important to remember that the interior materials we’ve just covered–conduit, rebar, and anchor bolts—aren’t included in a starter kit order for producing a Pole Base. You’ll be making each Pole Base exactly to your clients' specifications and can pick up these materials at your local hardware or concrete supply store as needed.

Pole Base starter kits, however, do include all the production equipment for getting your Pole Base operations up and running, including the Pole Base form, accessory items such as anchor bolt receivers, plastic mats for drilling bolt projections, conduit magnets, a rebar jig, and more. To discover the complete list of what’s included in your Pole Base starter kit, view: Getting Started With Pole Base: What’s in Your Starter Kit Order?

For more information on making Pole Base, check out the Make Pole Base site, where you can explore what producing Pole Base might look like for you, and move one step closer to creating built-to-spec, flawless light pole bases for your market.