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These step by step instructions show how to install an External Halyard Flagpole, the most commonly found type of flagpole!

Step 1. Prepare the Foundation

To begin, dig a hole for the foundation tube approximately five (5) times the butt diameter of the pole at the top and taper it down to four (4) times the butt diameter at the bottom. The depth should be approximately the corrugated tube length plus one (1) foot. See the table below for actual foundation dimensions.

Force the foundation tube spike into the ground until the small 6" x 6" rest plate reaches the bottom of the hole. Plumb the tube in both directions with a level.

Back fill with concrete mix (3000 psi min) to the top of the foundation tube in one pour without getting any concrete into the tube. Dress the top of the surface of the slab using a form if required.

Foundation Dimensions

A. Caulking: For a moisture seal, waterproof type caulking is applied approximately 2" deep around pole and between base or collar.

B. Flash Collar: Often used for appearance and added weather protection.

C. Pitch for Base: 1/2" to 1".

D. Grout Cap: l-2 mix, added for fine top finish.

E. Wood Wedges: Temporary, 4 used around pole for centering. Remove later.

F. Concrete Mix: 1-2-4 formula, complete in one pour.

G. Sand: Screened and dry. Tamp in.

H. Centering Wedges: Steel, welded to inside of foundation tube.

I. Tube: 18 ga. to 16 ga. galvanized corrugated steel.

J. Grounding Spike: 3/4" dia. x 18" to 24" Long total. welded to center and bottom of support plate.

Caution: Prior to performing these steps, make sure the halyard assembly is not attached to the pole or that any internal cable or rope is in the shaft. The cable or rope may get caught in the joint while assembling the shaft and prevent the shaft from going together. This will damage the cable or rope and may also damage the joint.

Step 2. Assembly of 2 & 3 Piece Flagpoles

Skip this step (Step 2) if your flagpole is one single pole shaft.

Lay the sections of the flagpoles on sturdy horses or blocks of wood so the ground will not damage the finish of the shafts.

Position the two sections of the flagpoles so that the lower field joint is aligned and ready to go into the top section of the flagpole. Caution: The field joint has been marked with identifying pole numbers, arrows or twin dots. Orient the pole with the pole numbers, arrows or dots so they line up together and be sure the pole numbers match. If numbers do not match stop and call FlagDesk at once!

Clean any dirt, rock, metal shavings and burrs from the inside of the bottom portion of the upper female section of the flagpole shaft and the outside of the top portion of the male section of the flagpole shaft.

Ram the two sections together as far as possible by hand, making sure the pole numbers, arrows or dots stay lined-up with each other. Caution: Before ramming the two sections together, consider icing the top portion of the male section for an easier fit. Another method is to lubricate the upper female section of the flagpole shaft and the outside of the top portion of the male section with grease or dishwashing liquid.

This operation may require a sledgehammer to drive the two sections together to within 1/16" of the joint. Always use a wooden protector between the hammer and the ends of the pole. The pole being aluminum can be damaged easily. Caution: Never drive the sections tight together.

Step 3. Attach Flagpole Components

You are now ready to attach the flagpole components to your shaft.

1. Locate truck with factory installed cable assemblies. For ease of assembly, the upper and lower cable assemblies have been pre-assembled.

2. Locate lower cable assembly; this will be the cable exiting from the threaded portion of the truck.

3. Using an electrical fish tape feed lower cable assembly through the 1-1/4" threaded hole at the top of the flagpole, pull lower cable through entire length of flagpole.

4. A 4" hole with a slotted keyway will be found about 5 ft. from the bottom of the pole. Using extreme caution, reach into this hole, grasp cable and pull about 4 ft. of cable through this hole. Use caution, the edhes of this hole may be sharp!

5. You should now have all but a few inches of the lower cable assembly inside of the flagpole, or at the lower end of the flagpole. If this is not tho case, then repeat steps 1 thru 5.

6. Screw the truck assembly into the top of the flagpole securely.

7. If steps 1 thru 7 have been satisfactorily completed, then you are now ready to install the Winch Assembly.

8. Locate the winch assembly. Remove the cylinder lock keys which are taped to the side of the winch assembly. Remove the hex drive countersunk stainless steel screw from the rear of the winch. Put keys and screw in a safe location. You will have to use them in a later step.

9. To remove the lock from winch, insert key, turn counter-clockwise and pull until the cylinder comes out.

10. Locate cable retaining hole and cable retaining set screw. With painted surface of winch in left hand and unpainted surface in your right hand, look into window of winch. You will see a 1/8" hole located on right side of the winch drum. This is the cable retaining hole.

11. Take loose end of cable that is protruding from the 4" hole and insert into the cable retaining hole. At this point it is important not to expose any cable on the other side of the drum.

12. Locate crank handle. Insert into recess and push in and turn clockise until cable retaining set screw is exposed .

13. Using appropriate size, align wrench and tighten set screw securely.

14. Using a square keyway as a pathway for the 1/8" cable, insert the cartridge into the 4" hole.

15. Locate 1/2" hole which is directly opposite the 4" hole. Align this hole with the hole in the cartridge, insert screw and tighten securely.

16. With cartridge winch properly installed. insert crank into crank socket, push in and turn clockwise until the upper cable starts to move toward the top of the flagpole.

17. Locate the rubber coated counterweight and attach temporarily to open chain link at loose end of the upper cable.

18. Screw the finial (ball, eagle, etc.) into the truck assembly and tighten with an open end wrench or an adjustable wrench (optional). Caution: The truck assembly is provided with a set screw for the ball. Make sure, prior to screwing the ball into the truck assembly, that the set crew is backed out so that it does not interfere with the threaded rod of the ball as it is being screwed into the truck assembly.

19. Lift the pole by an appropriate method, using care not to mark the pole surface.

20. Slip the collar up from the bottom and secure it to the cleat. Caution: Protect the pole with shipping paper underneath the collar to prevent scratching the pole.

21. Place the pole butt into the foundation tube and lower it to the bottom. BE SURE THE CLEAT IS POINTING IN THE DESIRED DIRECTION before doing any back filling of sand.

22. Make four (4) wooden wedges per drawing provided. plumb the pole in two (2) directions with a plumb bob, level or transit.

23. Fill the tube with loose dry sand. Make sure all the corrugations of the tube are filled. This is done by driving a stake to the bottom and moving it until the sand stops settling. The sand should come to within 2-1/2" - 3" from the top of the tube.

24. Remove the wooden wedges and pack the top of the tube around the pole with tar or silicone sealant to insure that moisture does not go into the foundation tube from the outside or that the sand can work it's way out of the tube.

25. Untie the collar and place it into position.

Flagpole erection is now complete. Caution: Do not fly a flag for at least four (4) days.

This entry was posted by Brent Alexander in How To's, Flagpole Install on March 31, 2012 at 3:47 PM. It has received 919 views and 1 Comments. Print this entry.