Bolt Star Reusable Bolt Template

2015 NOVA Award Nomination 2

BOLT STAR Reusable Bolt Template

TheBOLTSTARreusablebolttemplateisbecomingthenewindustrystandardforcastinplacepolebases.BOLTSTAR
eliminatestheneedtomakewoodtemplatesMadeofABSplas c,BOLTSTARisengineeredtoholdanchorboltsand
electricalconduitsneededtoerectalightpolesecurelyinplacewhilesuppor ngtherebarcageduringthepourofa
roundconcretepolebase.Thestructuralbasesarecommonlyspecifiedforparkinglotandoutdoorarealigh ng,street
ligh ng,securitycamerapoles,streetsignsandflagpoles.

BOLTSTAReliminatesthelaborintensivetaskoffabrica ngabolttemplateoutofwoodforeverypolebase.Theeasy
toinstalltooldeliversa57%moreecientconstruc onprocessthatcutssetup meinhalfandensuresaconsistent,
accurate,highqualitybase.Thereisnoneedtomeasure,cutordrillholes.Otheradvantages:1)crewscantrowelfinish
theen retopofthebaseimmediatelya erthepourwithoutremovingtheBOLTSTARtemplate.Thisensuresthat
boltsareheldsecurelyinposi onwhiletheconcretesetsup,loweringtheriskofcostlyreworkduetoboltsshi ingout
ofalignment;2)adjustableboltslotsgivecontractorstheflexibilitytoadjusttomanufacturersspecifica onsforapar
cularpole,inthefieldifnecessaryandaccommoda ngboltsizesfrom5/8to1indiameterandupto36inlength,
andboltcirclepa ernsrangingfrom7to14;and3)therebarcageiskeptcenteredintheconcreteform.

BOLTSTARsaves2030minutesoneachpolebase,reducingconstruc onwasteplusloweringtheriskofboltsshi ing

outofalignment.BoltStar'swidearmspromotefasterpourswithampleroomforavibrator.BOLTSTARisavailablein
18inchand24inchsizes.A30and36productareundergoingdevelopment.

Contractorsreportge ngsixreusesfromBoltStar.Inextremestresstes ngtosimulatethedownwardforcesonBOLT

STARduringacastinplacepour,productengineershungupto1,000poundsoa7footrebarcagethatwaswiredto
thecage eslotsattheendofBOLTSTARsarms.Therimoftheconcreteformingtubecollapsedat800pounds,but
BOLTSTARwasundamaged.Infurthertes ng,a6,000poundSUVwasdrivenoverBOLTSTARwithnodamage.
BOLTSTARsarmswerenotdesignedtobeadjustabletoprovidetheproductwiththemaximumstrengthanddurability
requiredduringcastinplaceconcretepours.

Theamountoflaborandmaterialsexpendedinbuildingawoodtemplateforeachpolebasevariesfrom$50to$100or
moredependingonlaborrates.BOLTSTARcutsthelaborpor oninhalf,andnoaddi onalmaterialsarerequiredto
buildfuturebolttemplatessinceBOLTSTARisreusable.

BOLTSTARfitsontheouterdiameterofnestedroundconcreteformingtubesusingtheXtenderadaptoraccessory.
Manufacturersofroundconcreteformingtubesinsomeregionsshipanominalorlargerouterdiametertubethatis
nestedorslippedovertheoutsideofstandard18or24tubestosaveonfreightcostsandstoragespace.Theselarg
erouterdiametertubesrangeinsizefrom19to19.4nestedoverthe18tube,andbetween25.2to25.5nested
overthe24tube.TheXtendersnapsontotheendofeachBOLTSTARarmandextendsittofittheselargerouterdi
ameternestedtubes.

BoltStarrequiresminorassembly:inser ngaboltthrougheachofBOLTSTARsfourarmsandthreadinganutonthe
otherend.TheboltscomewitheachBOLTSTARandkeepthearmssecuredtothehub.TheXtenderadaptorslipsup
andsnapsontotheendofeacharmwithnofastenersrequired.The30and36BOLTSTARversionsareinthedesign
stage.

BOLTSTARisthefirstnewproductofSacramentobasedConstruc onInnova ons.Theinventorsareelectriciansand

engineerswhorefinedtheideaforthisinnova veproductover10years.Theproductunderwentanintensivetwoyear
periodofdevelopmentandtes ngthroughacollabora veeortwithRexMooreElectricalContractors&Engineers.
Justeightmonthsa ershipmentsbeganin2013,BOLTSTARwasbeingusedbycontractorsin42states.BOLTSTARhas
ana onaldistribu onnetworkof400loca ons.BOLTSTARwontwopres giousawardslastyear:the2014TopProd
uctsawardbyElectricalProducts &Solu onsMagazineandacategorywinnerinthe2014ProductoftheYearcontest
sponsoredbyEC&Mmagazine.
Construction Innovation Forum 6494 Latcha Road, Walbridge, OH 43465 419-725-3108 Fax: 419-725-3079 Email: info@CIF.org www.CIF.org

Bolt Star

2015 NOVA Award Nomination 2

WithoutBolt
Star14steps

Construction Innovation Forum 6494 Latcha Road, Walbridge, OH 43465 419-725-3108 Fax: 419-725-3079 Email: info@CIF.org www.CIF.org