Application: Columbia flag hoist for raising the world’s largest American flag
Customer: ACUITY Insurance
Location: Sheboygan, Wisconsin
Hoist Model: Columbia AC Electric Hoist
Performance:
- Line Pull: 1,290 pounds
- Line Speed: Up to 80 feet per minute (variable)
- Wire Rope Capacity: 760 feet × 3/16″ wire rope
- Power Source: 230 VAC / Three Phase / 60 Hz
Special Features:
- Variable frequency drive with programmable speed control
- Wall-mounted control panel with keyed switch for security
- Custom gear reduction ratio for optimized performance
- Synchronized timing capability
Why APPI:
When ACUITY Insurance’s 150-foot flagpole was destroyed in a January 2005 windstorm, they saw an opportunity to demonstrate their values on a grander scale. Their vision: construct the tallest flagpole in the United States and fly the world’s largest American flag. They commissioned America’s Flags and Poles of Irving, Texas, to bring this ambitious project to life.
The scope of the project was extraordinary. Starting with a foundation pit measuring 22 feet in diameter and 35 feet deep, America’s Flags centered an 8-foot by 30-foot piece of corrugated pipe in the hole, added rebar, then poured over 550 cubic yards of concrete to secure the foundation. The first section of the flagpole was placed in the pipe, and the gap between it and the pipe was packed with sand—a design that allows the pole to move if the ground shifts and provides access for long-term maintenance.
Each section of the flagpole was then hoisted and welded into place one by one. The final piece of the ten sections required two cranes: a 500-ton capacity crane that hoisted the section and a 165-ton crane that supported welders in a man-basket while they joined the flagpole sections together.
With the pole completed, the total measured 338 feet to the top of the 6-foot diameter gold ball at its tip. This flagpole is not lightweight, weighing 65 tons and with the ability to flex up to 15 feet in high winds.
At 120 × 60 feet, the flag is just as impressive as the pole from which it flies. With 4½-foot-tall stripes and 3-foot-tall stars, it weighs a hefty 300 pounds and can be seen from over 20 miles away.
Given this massive flag’s weight, manual operation was quickly ruled out—it would take more than four times longer than desired to raise the flag. America’s Flags contacted Allied Power Products, Inc. (APPI) to collaboratively develop an automated solution that would meet their specific timing requirements.
Through their engineering discussions, America’s Flags and APPI jointly determined that a modified Columbia AC flag hoist would provide the ideal balance of power, speed, and control for this unique application.
Key features of this Columbia flag hoist system include:
- 3 HP motor with custom gear reduction – Engineered specifically to handle the 300-pound flag weight while achieving the necessary hoisting speed.
- Programmable variable frequency drive – Allows precise speed adjustment up to 80 feet per minute, enabling operators to synchronize flag raising time with the duration of the Star-Spangled Banner.
- 760-foot wire rope capacity – Provides the extensive length needed for the 338-foot flagpole with appropriate safety margin.
- Wall-mounted keyed control panel – Ensures authorized operation while providing convenient access for regular flag ceremonies.
This custom-engineered system offers ACUITY and America’s Flags several benefits:
- Synchronized flag ceremonies with musical accompaniment
- Efficient daily flag operations on the nation’s tallest flagpole
- Reliable automation eliminating manual hoisting challenges
- Safe, controlled raising and lowering of the world’s largest American flag
By implementing APPI’s Columbia flag hoist system, ACUITY created a lasting symbol of patriotism that has flown continuously since 2005. With six flags in rotation to manage wear, the system continues to perform reliably, raising and lowering the massive flag for ceremonies and weather conditions.
For more information about this Columbia flag hoist system or any of APPI’s other specialized products and services, please contact Allied Power Products, Inc. With over 40 years of experience in providing winches, hoists, capstans, and cranes tailored to specific application requirements, APPI continues to be a trusted partner for unique and challenging lifting applications.
