City of Gillette, Wyoming
Custom Light Pole Base Covers – Gillette Base
Project Year: 2015
Project Overview
The City of Gillette, Wyoming, faced ongoing maintenance challenges with its decorative aluminum light pole base covers. Due to the city’s extreme winter conditions—where temperatures drop below zero for more than half the year—along with heavy road salt usage, the aluminum bases corroded quickly, requiring frequent replacements and costly upkeep.
To address this issue, TerraCast® Products provided a long-term, maintenance-free solution by replicating the city’s existing base cover design using LLDPE resin. This innovative material is impervious to rust, resistant to harsh weather conditions, and requires no ongoing maintenance.
The Challenges:
Gillette faced a classic conflict between environmental challenges and infrastructure inadequacies. The city’s aluminum light pole bases were buckling under three relentless adversaries: extreme cold, exposure to road salt, and high maintenance costs. With temperatures plunging below zero for more than six months each year, the aluminum bases suffered from prolonged exposure to harsh conditions, which accelerated their wear and tear. Additionally, the metal’s vulnerability to thermal stress worsened the problem.
To maintain safe roads during Gillette’s brutal winters, the city used substantial amounts of road salt. While effective for melting ice, this salt severely damaged the aluminum bases, causing rapid corrosion and pitting that compromised their structural integrity and made them visually unappealing. The corrosion not only deteriorated the bases but also drained the city’s budget. Frequent repairs and replacements became a recurring expense, diverting resources from other important municipal priorities. Each rusted base served as a reminder of an unsustainable situation.
- Extreme Cold: Temperatures frequently drop below zero degrees Fahrenheit for over half the year.
- Road Salt Exposure: Heavy salt application for ice control led to rapid corrosion of aluminum base covers.
- High Maintenance Costs: The city had to regularly replace and maintain their aluminum base covers due to rust and damage.
The Solution:
After assessing Gillette’s needs, TerraCast proposed replacing the aluminum bases with covers made from LLDPE resin, a material that promised to transform the city’s maintenance challenges into a thing of the past. Working closely with Gillette, TerraCast carefully replicated the existing base cover design to maintain continuity in the city’s aesthetic while introducing several practical advantages, such as corrosion resistance, UV and chemical protection, and a maintenance-free lifespan. Unlike aluminum, LLDPE resin is resistant to rust and deterioration caused by salt. The heavy road salt that previously damaged metal bases became a non-issue, leaving the new covers intact year after year.
By choosing TerraCast resin base covers, Gillette was able to break the cycle of repairs and replacements. The durability of the material eliminated the need for ongoing maintenance, allowing municipal resources to be redirected to other projects. The TerraCast base covers are color-through, ensuring that they won’t fade under Wyoming’s intense sunlight. Moreover, any scratches or gouges resulting from exposure to the elements will be less noticeable due to the color-through material. This vibrant and consistent appearance helps preserve the aesthetic of Gillette’s streetscape over time.
By adhering to the original design specifications while using a superior material, TerraCast provided a solution that was both functional and aligned with Gillette’s vision. The transition to LLDPE resin marked a significant turning point in the city’s efforts to combat environmental wear.
TerraCast® Products replicated the design of the existing aluminum base covers using LLDPE resin, which offers several key benefits:
- Corrosion Resistance: Unlike aluminum, LLDPE does not rust or deteriorate from salt exposure.
- Maintenance-Free: The city eliminated costly repairs and replacements.
- UV Protection: Color-thru material prevents fading, ensuring long-term aesthetic appeal.
- Impact & Chip Resistance: Unlike metal or fiberglass, the material resists cracks, dents, and chipping.
The Result: 10 Years Later
A decade after the City of Gillette installed TerraCast’s LLDPE resin light pole base covers, the outcome has been remarkable: the city no longer has to worry about a once-persistent issue. Since their installation, these bases have remained in impeccable condition, showing no signs of corrosion, cracks, or fading—allowing the city to focus on other matters without a second thought. The maintenance-free promise of the TerraCast solution has exceeded expectations, enabling Gillette’s public works team to simply set it and forget it. There have been no repairs, no replacements, and no worries—just reliable performance year after year.
This change has been a game-changer. The recurring headaches and budget drains caused by the old aluminum bases are now a distant memory. Over the past ten years, Gillette has saved significantly on maintenance costs and has redirected those funds to other community priorities. Meanwhile, the bases continue to enhance the city’s streetscape, retaining their vibrant appearance despite the passage of time and exposure to the elements. For Gillette, TerraCast didn't just solve a problem—it completely eliminated it, providing a decade of effortless resilience.
Key Takeaways
The City of Gillette’s partnership with TerraCast® Products serves as a shining example of how innovative solutions can effectively address municipal challenges. By replacing corroding aluminum bases with LLDPE resin covers, Gillette transformed a costly and recurring problem into a one-time fix with lasting benefits. A decade later, the results are evident: zero corrosion, minimal maintenance, and a streetscape that still shines.
For other cities facing similar environmental challenges, Gillette’s experience provides a valuable blueprint. TerraCast’s ability to customize solutions to precise specifications—while utilizing the exceptional properties of LLDPE resin—shows that durability and design can coexist harmoniously. In Gillette, the light pole bases are no longer a weak link; they have become a symbol of resilience, demonstrating that the right material can truly make a difference.
- Material matters: LLDPE resin offers superior durability over traditional aluminum.
- Cost savings: Eliminating corrosion-related maintenance leads to significant long-term savings.
- Sustainability: Longer-lasting materials reduce waste and resource consumption.
About Us
All of our products are made in America. All offices, warehouses, facilities and factories stand proud on US soil. Originally founded in 1969, we have remained an American owned and operated company.
Our Products
A Terracast® product is designed to beat out the competition in every conceivable way. Our products are customizable, lightweight, weather/graffiti resistant, eco-friendly, and almost indestructible.
Contact Us
When you contact Terracast® you will always be met with a friendly voice. We want to make sure you are well taken care of whether you're a new customer or have been doing business with us for 20 years.