**Abstract**

Welded aluminum light poles often contain hand-holes. These hand-holes are used to give access for electrical wiring installation and maintenance purposes. Wind load may cause light poles to be loaded in a cyclic manner. This cyclic loading can cause localized fatigue cracking around the hand-hole. Fatigue failure around hand-holes has been observed in the field, but studies surrounding the resistance of the handholes are few and far between. This study included four-point bending fatigue tests on welded aluminum poles containing hand-holes. Eight welded aluminum specimens, each with two hand-holes, were tested in fatigue. These 16 details were loaded at the same stress range. Each specimen had a slightly different geometry or treatment applied to the hand hole. These different details mimicked traditional reinforced hand holes, similar to those evaluated in previous studies. Changes in the treatment and/ or geometry included milling the inside of hole, milling the inside of the hole as well as the cast insert prior to welding, and milling the cast insert itself prior to welding. Among the 16 details tested, 15 failed as a result of fatigue cracking. It was found that specimen failure would originated in the throat of the fillet weld and then proceeded to propagate into the reinforcement ring/casting. A finite element analysis was used in addition to the experimental study.

**Keywords:** fatigue test, static test, welded aluminum hand-hole details, design S-N curve, high cycle fatigue
