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 compos- ite utility poles, it turned to pull-winding spe- cialist Exel Composites. EasyStreet Systems specializes in pro- viding and installing small cell infrastructure solutions using advanced composite materials. The company’s towers, previous- ly constructed from carbon fiber, serve as versatile platforms for a wide range of applications, including 4G/5G small cell deploy- ments, IoT sites, and smart city initiatives. Composites are used in their products to deliver lightweight, durable, and aesthetical- ly pleasing infrastructure solutions. The company also offers customization for each installation, providing the flexibility to integrate a diverse array of technolo- gies. From basic security cameras to smart lighting, all the way to sophisticated light detection and ranging (LIDAR) sensors, Wi-Fi access points, electric vehicle chargers, and power meters. This provides comprehensive solutions that address the evolv- ing needs of modern infrastructure projects. In the UK alone, the telecom market is estimated 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 car- bon fiber. Despite the material’s initial advantages, its slow pro- duction process became a bottleneck, impeding EasyStreet Sys- tems’ ability to scale and meet market demands. This predic- ament prompted a pivotal decision over material choice - one that led to a collaboration with specialist composite manufac- turer Exel Composites. - Carbon fiber filament winding was too slow for our produc- tion 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 manufacturing of composites, emerged as a partner in address- ing EasyStreet Systems’ production challenge. As a frontrunner in pultrusion and pull-winding composite manufacturing, Exel Composites was uniquely positioned to provide tailored solu- tions 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 production constraints that were hinder- ing business scalability,” explained Juha Pesonen, telecommu- nications 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-wind- ing manufacturing technique to produce glass fiber compos- ite utility poles. In addition to the unidirectional alignment of fibers, the pull-winding process uses helical winding of rein- forcements. This mix of fiber directions allows for advantag- es such as thinner walls and meeting specific strength or stiff- ness 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 supe- rior strength and durability. For example, fiberglass composites exhibit a higher strength-to-weight ratio, with flexural 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 installation 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 composites means that its installation requires minimal equipment and per- sonnel for installation, translating into cost savings and acceler- ated project timelines.
22 MUOVIPLAST 6/2025
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