Project Overview
State Line Foundries is known for tough, industrial castings used in pumps, mining equipment and military vehicles. But when a decorative casting project came along, it opened the door to something different: applying heavy-duty foundry expertise to a highly visible, design-driven application.
LampLight Decorative Lighting needed a foundry to produce decorative bases for new 5G smart poles being installed across New Orleans. Deployed by the Toro Blanco Group, the poles support next-generation voice and data services – while still blending seamlessly into the city’s historic streetscape.
The goal was simple to describe and difficult to execute: deliver castings strong enough for modern infrastructure without sacrificing classic, ornamental detail.
Finding the Right Partner
LampLight, a supplier of configurable and custom outdoor lighting components, required a foundry capable of executing a complex decorative design with precision. A web search led them to State Line Foundries, and early conversations confirmed the foundries’ technical depth and the willingness to step beyond its traditional projects.
“They were excited to take on something different,” says Chris Morris, owner of LampLight. “They were responsive, collaborative and focused on getting the details right.”
The Scope
- Decorative bases: 150
- Total castings: 300 half-bases
- Height: ~5 feet per base
- Weight: Over 600 lbs each
- Material: Ductile iron
- Design highlight: 45-degree rope pattern
- End use: 5G smart pole infrastructure
Each base was cast in two halves that bolt together around the pole. After casting, LampLight drilled and tapped bolt holes, primed the components and shipped them to New Orleans. There, the bases were painted to match the city’s historic streetlamps – and then installed.
Key Challenges
Decorative detail with zero compromise
The rope pattern created undercuts near the parting line. Standard draft angles or added material would have changed the look – an option that simply wasn’t on the table.
Challenging pattern geometry
Angling the rope detail at 45 degrees was essential to the design. Flattening it would have simplified the pattern but undermined the aesthetic.
A finish fit for public view
Early test castings showed grinding marks where in-gates were removed. This is acceptable for industrial parts, but not for a decorative base meant to be seen up close.
State Line’s Approach
A high level of coordination, commitment and creative thinking were required. How did State Line meet the deadlines – and deliver quality?
- Detailed Gantt charts were developed to map every phase: engineering, tooling, casting, finishing and shipping.
- Internal scheduling issues were identified early and corrected before they became delays.
- Production meetings of 10-15 minutes were held to align sales, production, management, plant leadership, pattern shop and foundry teams.
- Meetings also included planning to keep other projects on schedule.
- Casting production began immediately with the 11 existing patterns.
- New pattern tools were built and introduced into production as they were completed, rather than waiting for all 14 to be finished.
- Regular progress updates were provided to ensure transparency and build confidence.
- State Line hosted customer visits during the process to maximize communication and collaboration.
- State Line handled the entire project end-to-end across multiple stake holders: customer, engineers, pattern shops, raw material vendors, production, freight, etc.
- The foundry’s experience and technology ensured the challenging alloy was handled with ease.
- The customer benefited from a single point of contact, one purchase order and unified communication – rather than managing multiple vendors.
The Results
- Decorative castings that met both structural and aesthetic requirements
- Clean, consistent seam alignment between halves
- Finished poles that fit naturally into New Orleans’ historic streetscape
- A successful expansion into decorative casting work for State Line
From the customer’s side:
“We work with several foundries in the Midwest and Southeast,” Morris says. “State Line earned a spot on that list.”
From the foundry’s side:
“We don’t often get to make something this ornamental,” Milks adds. “The team loved seeing their work become part of the New Orleans streetscape.”
Looking Ahead
Following the success of this project, LampLight has continued sending work to State Line Foundries – proof that flexibility, craftsmanship and collaboration can open doors well beyond traditional industrial casting.
Have a project that demands strength and style? Contact State Line Foundries to ensure you get both!