Project G922 – Custom Steel Lighting Poles for EU Municipal Infrastructure

Engineering-Led Case Study – On-Site Validation for EU Municipal Infrastructure

On-site engineering validation and quality control of custom steel lighting poles for EU municipal infrastructure, including dimensional inspection, welding verification, electrical safety testing, and pre-production engineering correction.

Custom Steel Lighting Poles for EU Municipal Infrastructure - Project Overview

Project Code: G922
Product: Custom-designed steel lighting poles
Application: Urban public lighting infrastructure
Scope: Engineering validation, dimensional control, production supervision, electrical safety verification, and pre-shipment inspection
Market: 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.

Technical drawings and dimensional specifications for custom steel lighting poles, including base fl

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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.

Dimensional inspection of steel lighting pole during on-site quality control – Project G922

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Inspection report project G922 - proof

Project-G922-On-Site-Inspection-Report.pdf

Functional test

Functional lighting test – red output – Project G922

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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.

Welding inspection and structural verification of curved arm on steel lighting pole – Project G922

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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.

Electrical safety components verified for EU compliance in Project G922

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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.

Electrical safety HI-POT testing performed on municipal lighting components – Project G922

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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.

Certificate of Conformity issued for components used in Project G922 municipal lighting infrastructu

CE EMC test report documenting electromagnetic compatibility compliance for Project G922

Additional CE EMC laboratory test report for Project G922 component validation

Verification of Compliance document supporting CE conformity for Project G922

CE EMC compliance test results for electrical components used in municipal lighting project G922

EU Declaration of Conformity issued for Project G922 municipal lighting system

Inspection certificate documenting quality control checks for Project G922 production

Signed Verification of Compliance confirming regulatory conformity for Project G922

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Powder-coated steel lighting poles aligned after surface finishing inside production facility – Proj

Batch of custom steel lighting poles arranged for visual and finish uniformity inspection – Project

Final batch of custom steel lighting poles staged for packaging and logistics preparation – Project

Straightness and dimensional verification of individual steel lighting pole on factory floor – Proje

Machined base and flange openings on custom steel lighting poles prior to packaging – Project G922

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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

Alignment and positioning of wrapped steel lighting poles during loading to prevent deformation – Pr

Sealed export container with SHAMANA identification after supervised loading of steel lighting poles

Protective end wrapping applied to steel lighting pole bases to prevent impact damage during transpo

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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

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.

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