Meeting tough quality standards Exel Composites encountered several challenges during the development and implementation of the utility poles, primarily related to regional standards and manufactur- ing optimization. For example, the wind speed, temperature, and climate in the northern US is completely different to that in the south, necessitating different infrastructure standards to manage the difference in conditions. Meeting these standards required rigorous testing and certification processes to adhere to industry regulations effectively in a single product, rather than producing different tubes with different properties dependent on the region. Another of the technical challenges faced was addressing wind deflection and stability in the utility poles, crucial factors for their performance, especially in high wind-speed environ- ments. Traditional filament winding techniques resulting in transverse fiber orientations, leading to pole deflection under high wind loads whereas pull-winding makes it possible to place and align fibers in axial directions due to the thin transverse lay- ers leaving room for the axial fibers. This enhances the pole’s rigidity, reducing wind deflection. Extensive simulations were conducted to assess the wind deflection characteristics of the poles under various condi- tions. These simulations, using Finite Element Analysis (FEA) tests, provided valuable insights into the structural behaviors of the poles and informed design refinements to augment per- formance. By making the wall thinner and improving material usage through pull-winding, Exel Composites achieved the same wind-deflection targets as the original carbon fiber tubes with less material used compared to traditional pultruded glass fib- er poles, further reducing the overall weight to be closer to that of a similar carbon fiber tube. Additionally, as pull-winding is a continuous process, it allowed for the efficient production of large volumes enabling Exel Composites to meet the demand of EasyStreet Systems while maintaining consistent quality. Saving time, costs, and resources The collaboration has resulted in significant benefits for EasyS- treet Systems’ utility infrastructure projects. Exel Composites’ establishment of an ISO9001:2015 compliant manufacturing facility in the USA has bolstered EasyStreet Sys- tems’ production capacity, resulting in shorter lead times, and improved operational efficiency. Moreover, the use of composite poles eliminates the need for toxic preservatives normally associated with wooden poles, as well as doubling the lifespan of these telecommunications poles to 70 years [7], compared to the assumed 30–40-year lifespan
[8] of wood- en poles. This, along with the local manufacture and lightweight nature of the
poles, contributes to an overall carbon footprint reduction [9], while the continu- ous manufacture of the poles enhances material usage and min- imizes waste. Glass fiber composites are also compliant, the material is accredited by the National Electric Safety Code (NESC 2012) as being as reliable as steel equivalents. The material has also been recognized for its grid resilience in extreme weather, its high dielectric strength and 80 per cent lighter than steel and two hundred per cent stronger than wood. - As a result of this collaboration, we can produce poles much quicker than before, as well as save money due to the price dif- ference between glass fiber and carbon fiber, added Pete Chase, CEO at EasyStreet Systems. [1] https://easystreetsystems.com/applications [2] https://www.mordorintelligence.com/industry-reports/ united-kingdom-telecom-market/market-size [3] https://www.mordorintelligence.com/industry-reports/ united-kingdom-telecom-market/market-size [4] https://www.sciencedirect.com/science/article/pii/ S2238785423018483 [5] https://www.atlasfibre.com/understanding-flexural- strength-guide-to-flexural-strength-in-materials/ [6] https://www.researchgate.net/publication/307587235_A_ comparative_Life_Cycle_Assessment_of_utility_poles_ manufactured_with_different_materials_and_dimensions [7] https://generalstructuresinc.com/blog/which-light-pole- material-is-best-for-your-project/ [8] https://woodpoles.org/portals/2/documents/ TB_ServiceLife.pdf [9] https://www.researchgate.net/publication/307587235_A_ comparative_Life_Cycle_Assessment_of_utility_poles_ manufactured_with_different_materials_and_dimensions
About Exel Composites Exel Composites is one of the largest manufacturers of pultruded and pull-wound composite profiles and tubes and a pultrusion technology forerunner in the global composite market. Headquartered in Finland, Exel Composites employs over 600 forward-thinking professionals around the world and is listed on Nasdaq Helsinki. To find out more about our offering and company please visit www.exelcomposites.com.
6/2025 MUOVIPLAST 23
Made with FlippingBook - Online magazine maker