Reaping the benefits of pull-winding in utility infrastructure
Text and photos: Excel Composites
W hen Telecommunications and utility pole [1] specialist, EasyStreet Systems needed to scale manufacturing of its carbon fiber composite utility poles, it turned to pull-wind- ing specialist Exel Composites. EasyStreet Systems specializes in pro- viding and installing small cell infrastructure solutions using advanced composite materials. The company’s towers, previously constructed from carbon fiber, serve as versatile platforms for a wide range of ap- plications, including 4G/5G small cell deployments, IoT sites, and smart city initiatives. Composites are used in their products to deliver light- weight, durable, and aesthetically pleasing infrastructure solutions. The company also offers customization for each installation, provid- ing the flexibility to integrate a diverse array of technologies. From basic security cameras to smart lighting, all the way to sophisticated light detection and ranging (LIDAR) sensors, Wi-Fi access points, electric
pull-winding composite manufacturing, Exel Composites was uniquely positioned to provide tailored solutions that would not only meet but exceed the expectations of EasyStreet Systems. “The brief from EasyStreet Systems to Exel Composites revolved around the need for a material solution that could match the strength and lightweight properties of carbon fiber while addressing the pro- duction constraints that were hindering business scalability,” ex- plained Juha Pesonen, telecommunications segment owner at Exel Composites.” The challenge prompted us to innovate and develop a solution that not only met but surpassed the stringent requirements outlined in the brief.” Exel Composites proposed a solution leveraging the pull-winding manufacturing technique to produce glass fiber composite utility poles. In addition to the unidirectional alignment of fibers, the pull-wind- ing process uses helical winding of reinforcements. This mix of fiber directions allows for advantages such as thinner walls and meeting specific strength or stiffness requirements. In EasyStreet’s case, pull-winding enabled poles that, while 25 per cent heavier than carbon fiber, were still lighter than traditional steel and wood poles and boasted superior strength
vehicle chargers, and power meters. This provides com-
prehensive solutions that address the evolving needs of modern infra- structure projects. In the UK alone, the telecom market is estimat- ed to grow by nine billion dollars [2] in the next five years, and the Government is targeting total fiber coverage by 2033 [3]. As the demand for small cell infrastructure skyrockets, EasyStreet Systems faced limitations in its production capacity due to its reliance on carbon fiber. Despite the material’s initial advantages, its slow production process became a bottleneck, impeding EasyStreet Systems’ ability to scale and meet market demands. This predicament prompted a pivotal decision over material choice — one that led to a collaboration with specialist composite manufacturer Exel Composites. — Carbon fiber filament winding was too slow for our production needs, and we wanted a single source that could produce all of our product, while maintaining quality control, explained Kent Harrison, CTO of EasyStreet Systems. And continues: “We had to search for a supplier that could meet our demand, we needed a solution that could be produced quicker and cheaper but would perform equally well.” The pull-wound solution Exel Composites, an industry leader specializing in continuous manu- facturing of composites, emerged as a partner in addressing EasyStreet Systems’ production challenge. As a frontrunner in pultrusion and
and durability. For example, fiberglass composites ex- hibit a higher strength- to-weight ratio, with flex- ural strength reaching up to 1000 MPa [4] compared
to steel’s 370–520 MPa [5]. Furthermore, Exel Composites’ pull-
wound fiberglass poles offered tangible benefits in terms of installa- tion efficiency. The weight of fiberglass poles makes them easy and quick to install, reducing installation time by up to 70 per cent [6] compared to steel poles. The lightweight nature of fiberglass compos- ites means that its installation requires minimal equipment and per- sonnel for installation, translating into cost savings and accelerated project timelines. Meeting tough quality standards Exel Composites encountered several challenges during the develop- ment and implementation of the utility poles, primarily related to re- gional standards and manufacturing optimization. For example, the wind speed, temperature, and climate in the northern US is complete- ly different to that in the south, necessitating different infrastructure standards to manage the difference in conditions. Meeting these stand-
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