ACMA CCT Composite Utility Pole Training Course PDF

Fiberglass Reinforced Polymer (FRP) Composite ​ Utility Pole Training Created by: ​ Course​ American Composites Manufacturers Association (ACMA)​ Utility and Communications Structures Council © 202...

Fiberglass Reinforced Polymer (FRP) Composite ​ Utility Pole Training Created by: ​ Course​ American Composites Manufacturers Association (ACMA)​ Utility and Communications Structures Council © 2025 American Composites Manufacturers Association (ACMA). All rights reserved. This document and its contents are the property of the American Composites Manufacturers Association (ACMA). No part of this presentation may be reproduced, distributed, or transmitted in any form or by any means, including photocopying, recording, or other electronic or mechanical methods, without the prior written permission of ACMA, except in the case of brief quotations for use in reviews or academic purposes.  Meet Your Instructors Name Name Name Compan Compan Compan y y y Disclai mer The guidelines contained in this course are published by the Utility and Communications Structures Council of the American Composites Manufacturers Association (ACMA) as an educational service to manufacturers, retailers, consumers and other users of composite poles and crossarms.​ The information and procedures contained in this publication have been compiled from sources believed to be reliable. They are not intended to represent the exclusive, or necessarily the best, most acceptable or safest procedures for the installation of products. Under certain circumstances or conditions, additional or different procedures may be required.​ ACMA makes no express or implied warranty, guarantee or other representation, express or implied, as to the validity or sufficiency of any procedure, or related information, contained in this course. ACMA assumes no responsibility for any property damage, including but not limited to damage to any material, or personal loss or injury that may result from the use or misuse of these procedures nor from any other information contained In general,herein.​ participants of the composite pole training should properly wear PPE and inform the program instructor of the need to repair or replace PPE. 3 About ACMA ACMA is committed to supporting the industry to make composites the sustainable material of preference and enabling a better future for our members, partners, and society. The American Composites Manufacturers Association (ACMA) is the world’s leading composites industry trade group. ​ Delivers education and events, access to market intelligence, and by working with regulators and legislators, ACMA serves as the center of expertise and competence. ​ Our purpose is to help composites manufacturers prosper by supporting the industry in delivering composite technologies that make structures more durable, transportation more efficient, consumer & industrial goods higher performing while minimizing their environmental footprint and supporting the workforce that delivers them. ​ 4 Thank You! ACMA thanks the following manufacturer members of the Utility & Communication Structures Council for their support in the development of this course material.​ 5 ACMA’s Utility & Communication Structures Council Promote the safe use of Fiberglass Ensure aspiring lineman are 1 Reinforced Polymer (FRP) composite properly trained in working with poles and crossarms for electrical FRP composite poles. distribution, transmission and communication structures, and applications for power delivery and infrastructure.​ 6  Learning Objective ​After successful completion of this course, apprentices should be able to: ​ Receiv Insta Clim Cut Dril e ll b l Rep Ground Inspe Remov Dispo air ct e se 7 Training Course Outline 1. About FRP Poles 2. About Composite Materials 3. Handling, Drilling, & Cutting 4. Installing & Climbing 5. Repairing 6. Removing 7. Disposing 8. Hands-on Field Demonstration 8 Section 1: About FRP Poles 9 Types of FRP Poles FRP poles find application in both distribution and transmission portions of an electrical grid.​ Configurations Monopoles are non-tapered​ Modular or sectional poles are tapered 10 Benefits of Composite Materials for FRP Poles Resilient​ Safe​ FRP poles offer proven Ground wires and communication performance in major weather cables can be run inside the pole for events including ice storms, protection and to eliminate ground wire tornados, hurricanes, and theft.​ extreme winds. Lightweight​ Environmentally FRP poles tend to be 2 to 4 times Sustainable Poles use non-leaching materials that lighter than wood poles, create no soil remediation requirements decreasing installation time while or end-of-life disposal issues. enhancing worker safety. High Dielectric Strength​ Rust and Rot Proof Increased insulation strength Resistance to rot and rust reduce provides enhanced safety to maintenance needs and expand the linemen and wildlife. overall lifetime of the pole. High Strength​ Self-Extinguishing High fracture toughness allows Most poles will self extinguish if absorption of elastic strain ignited due to a fire. 11 energy​. Ideal Applications Anti-cascading Grid hardening ​ structures ​ Areas requiring increased Hurricane, tornado, microburst aesthetics ​ prone areas ​ Avian and wildlife Increased line Basic Insulation protection​ Level (BIL) Coastal, wetland, bog Repeat grass or brush fire- areas ​ prone areas​ Difficult or remote access Rough terrain and forested areas locations ​ Emergency or storm Woodpecker, termite, ant, stock prone areas Environmentally sensitive areas ​ 12 Section 2: About Composite Materials 13 What are Composites? Composites are materials created by the combination of two or more materials, on a macroscopic scale, to form a new and useful material with enhanced properties that are superior to those of the individual constituents alone​. Fiber Reinforced Polymer (FRP) composites​are engineered materials comprised of a fiber, from which the product derives its strength, and a thermoset resin, that binds the fibers together and transfers stress to the fibers. Common fibers include glass, carbon, basalt, and aramid. E-glass is primarily used in the manufacture of FRP poles. Common resins (or matrix materials) include polyester, vinyl ester, epoxy, or polyurethane. 14 Making Composite Materials Fibers and matrix both play critical roles in the make up of composite material; together they create a material with attributes superior to either component alone!​ Fiber Matrix Composite 15 Fiber Reinforcements Provide Strength Roving is the most common form of glass reinforcement and can be chopped fiber, woven fabric, or further processed to create additional forms:​ Mats are non- Fabrics can Veil is a surface layer that woven and available be woven or supports the outer resin and as chopped or stitched. creates a smooth surface and continuous strand. provides UV protection. 16 Common Electrical Applications 17 Common Infrastructure Applications 18 Common Bridge Products & Applications Bridge pier protection systems (fenders) Cantilever sidewalks (walkway, bike paths) Concrete reinforcement (rebar, tendons) Benefits: Corrosion resistant Concrete strengthening systems Design flexibility (wraps, plates, rods, rebar) Fast assembly & Drainage pipes installation Benefits: Girders High strength Lightweight Piles (fender, bearing, Little-to-no maintenance sheet) Lower installation costs Vehicular decks and pedestrian bridges (decking, railing, supports)​ Modular, factory-made with built-in details Wind fairings Worker safety 19 Section 3: Handling, Drilling, & Cutting 20 Equipment Summary – Handling, Drilling, & Cutting Nylon sling with neoprene or rubber coating and appropriate capacity Personal Protective Equipment (PPE) Proper care when cutting banding Pole trailer 21 General Handling Guidelines Lightweight composite poles can be hand- carried in teams of two, using nylon slings​. A boom truck with a nylon sling can be used to handle larger poles.​ The practice of skidding is not recommended for FRP composite poles. Instead use a dolly or other means to transport the pole to the set site. 22 General Handling Guidelines The nominal weight of each pole is identified on the ID tag positioned approximately 10’ – 13’ from the bottom of the pole. Center of gravity will be marked on the pole or on the manufacturer’s drawing. Pick the pole at the center of gravity marker for ease of maneuverability. Like wood poles, FRP poles can be picked with a utility truck. 23 General Handling Guidelines Poles can be repicked by sliding the sling up the pole a few feet to make the bottom of the pole heavier. Pole caps can be removed in some scenarios to add ballast material inside the hollow pole and shift the center of gravity for easier pole placement in live conductors. This action will permit the boom of the truck to be lower on the pole. 24 Unloading in the Pole Yard Typically, poles are shipped via flatbed truck in bundles designed for safe loading, shipping, and unloading. Freight and logistical considerations: Bundles typically include 3 or 4 poles Poles can ship ready to install or as nested sections Designed to be lifted at scuff-protected Never pick center a pole with a lift truck without proper scuff protection. Scraping damage to the pole could weaken the pole’s resistance to UV light. Always work with manufacturer for detailed delivery requirements. 25 Setting Poles Pick the pole in the same manner as a wood pole. In the event you are concerned with the slide on the choker, simply place a through bolt above the choker. It is acceptable and often unavoidable to scuff the UV coating on portions of the poles that are below grade. Dragging the butt of the pole is necessary and permissible during the set. 26 Sectional Pole Assembly Ensure both the outer tip of the larger (lower) section and the inside of the smaller (upper) section are clean and free of any debris. Guide the modules together: This is a pinch point; keep fingers clear of the module’s edge Use manufacturer’s alignment marking Pole stands are recommended Mechanically fasten slip joint once complete. Follow manufacturer’s recommended assembly method and use correct amount of force. 27 General Handling Recap Do Not: Drag the poles to the set site or use metal chains or chokers DO: Use dollies for transporting poles any distance. 28 Drilling Holes – Recommended Drills and Bits Hardened high-speed steel (HSS) twist drills Carbide tipped twist drills Diamond coated hole saws Brad-point HSS twist drills Milwaukee SHOCKWAVE Impact Duty™ Lineman’s Fiberglass Drill Bits 29 Drilling Holes Edge distance chart: As a rule, keep the gauge, end, and pitch spacing greater than (4) bolt diameters apart. Minimum hole spacing shall be selected by referencing the Edge Distance Chart. 30 Video: Drilling Holes 31 Cutting FRP Poles Composite utility poles can be field-cut using these types of saws: Circular Concrete Reciprocatin g Recommended blades include: Milwaukee Diamond Premium Segmented Blade Milwaukee Carbide Reciprocating Saw Blade Always use an abrasive blade. 32 Dust Glass fiber potentially contained in FRP dust can cause irritation or itching if it is in contact with skin or mucus membranes. This is due to mechanical abrasion and is not an allergic effect. 33 Dust – OSHA Regulations Inhalation of the dust from a composite pole can cause irritation of the respiratory system. OSHA considers these dusts to be “Inert/Nuisance Dusts” or “Particulates Not Otherwise Regulated (PNOR)” and has established a workplace Permissible Exposure Limit (PEL) of 5 mg/m3 for the PNOR respirable fraction and 15 mg/m3 for PNOR as total dust.1 For dust comprised of the continuous filament glass fibers used to manufacture composite poles, the American Conference of Governmental Industrial Hygienists has established a Threshold Limit Value (TLV, a recommended workplace exposure limit) of 1 fiber/cm3 for respirable fibers and 5 mg/m3 for inhalable glass fiber dust.2 Cal-OSHA has adopted the TLV in their state plan as a state permissible exposure limit.3 34 Dust – Recommended PPE When cutting and drilling FRP poles, composite utility pole manufacturers recommend use of the following personal protective equipment (PPE): Particle mask Safety glasses Gloves Hard hat Long sleeve shirt and long pants Safety footwear 35  Dust – References 1. OSHA Occupational Chemical Database: Fibrous Glass Dust: https://www.osha.gov/chemicaldata/805 Mineral Dusts for Inert or Nuisance Dust: https://www.osha.gov/laws-regs/regulations/standardnumber /1910/1910.1000TABLEZ3 Particulates Not Otherwise Regulated, Total and Respirable Dust: https://www.osha.gov/chemicaldata/801 2. https://www.acgih.org/synthetic-vitreous-fibers/ 3. https://www.dir.ca.gov/title8/5155table_ac1.html 4. “Continuous Filament Glass Fibre and Human Health”: https://www.glassfibreeurope.eu/wp-content/uploads/ 2022/09/GFE_leaflet-Human-Health-November-2021.pdf 36 Takeaway Use of slings and pick up points requires close attention Use best practices to protect UV surface of composites Like a galvanized steel pole, take care to not compromise the surface. Neoprene coated slings work the best and mitigate the pole from slipping. 37 Section 4: Installing & Climbing 38 Equipment Summary – Installing & Climbing Installi ng Pole Cant steps tool Nylon sling Laser level or choker plumb bob Climbin g Fall protection Step attachments with appropriate weight capacity Transporting Modular pole sections may be nested within one another. Extended trailers may be required for non- modular poles. 40 Video: Setting FRP Poles 41 Burial Depth Equation Industry Standard Burial Depth is (Overall Pole Length x 10%) + 2’ Burial depth may differ based on soil conditions and engineering requirements Example burial depth equation: Pole length = 50’ (50’ x 10%) + 2’ 5’ + 2’ = 7’ burial depth 42 Lifting Use choker sling to lift and place pole in the hole. 43 Alignment Cant tool can be used to turn pole in the hole to align rotationally. Either a laser level or plumb bob can be used to plumb the pole​ A symmetrical, well balanced pole results in easy and precise alignment. The pole should be raked for dead-end and unguyed applications, the same as a wood pole. 44 Embedment & Backfill Direct bury or place inside a preinstalled corrugated tube and backfill accordingly. Surface mount and other foundation options available, but rarely used. Backfill options: ¾” minus graded aggregate Pole foam On some occasions, concrete can be used to backfill. Native soil 45 Climbing using 3-point Contact Requirements Ascending and descending: 1. Feet 2. Hands 3. Pole strap (fall restrict) While 1. Feet working: 2. Pole strap (fall restrict) 3. Lanyard (fall arrest) Always use a pole strap or lanyard as one of the three contact points. 46 Step Attachments: Permanent vs. Removable Be aware that there are different types Understand equipment needed Understand weight limits 47 Fall Protection Cannot use traditional wood pole climbing equipment Follow safety protocol procedures per your utility 48 Framing Always use smooth backed, non-cleated hardware or tools. Do not use hardware that is designed to be drawn into the pole. All load bearing attachments should be secured using through-bolts. Torque limit recommendation: 50 ft-lbs or hand tightened plus one-half turn Composite inserts are available to help prevent over- torquing of bolts and aid in bolt installation. Lag screws or self-tapping screws can be used for non-load bearing attachments such as U-Guard or bottom holes on streetlight mounts. Pilot holes recommended. Do not install heavy equipment on the ground. The pole must be properly set and raked before heavy equipment is installed. 49 Video: Framing 50 Guying an FRP Pole Use non-cleated hardware. Curved washers recommended by pole manufacturer must be placed on the backside of a guy connection. Through-bolts should be used for mounting hole, lag screws may be used for lower holes. Recommend using oversized steel washer on back side of connections that resist a horizontal load. Standard hardware can be used for vertically induced loads such as a transformer. 51 Grounding Ground wires can be attached via wire clips and self- tapping screws. Ground wire can be run using a combination of internally or externally and can be done at the manufacturer’s location or in the field. Internal grounding: Prevents copper theft or tampering and provides a more aesthetically pleasing pole. External grounding: Provides for easier inspection and access. Combination: Ground wire can be run externally down to 10’ – 20’ above ground line, then internally to below the ground line. Ground wire may exit slightly above or below the ground line for attachment to ground rod or plate. 52 Banding for Connections Pole band hardware is available in a range of styles and load capabilities. Bands can be used to connect various hardware to an FRP pole including: Communication cables Guy wires Streetlig hts Conduit 53 Attaching Conduit Attachment options include: Double hold down clips with self-tapping screws Stand-off brackets with through bolts 54 Takeaway Installation of directly embedded poles is very similar to wood poles Always use non-cleated hardware All load bearing equipment must be through-bolted Torque limit recommendation: 50 ft-lbs. 55 Section 5: Repairing 56 Equipment Summary – Repairing FRP Poles Equipment specific to the manufacturer’s repair method may vary. Consult the manufacturer’s repair manual. 220 grit sandpaper​ Putty knife​ Paint brush 3MTM Short Strand Reinforced Filler (for shallow scratches) Sika® Axson Technologies APF7 Polyester Filler (for deep gouges)​ Two-part acrylic polyurethane paint such as Sherwin-Williams Acrolon® 218 HS 57 Damage Inspection Visual inspection is most common for surface damage assessment and used to inspect for: Tracking or lightning damage Vandalis m Laminate damage due to hardware connections Impact near ground line Delamination or fiber bloom A tap test is often used to identify suspected localized damage that may not be visible A coin or similar metal object is used to lightly tap the suspected damaged area. sharp “ping” should be heard on an in-tact pole; a A high-pitched, dull thud will be heard if there has been damage to the pole wall laminate. 58 Visual Inspection Cosmetic surface coating damage includes scrapes, cuts, or peeling. Structural fiber breakage or gouges typically result from impact, collision, or weather events.​ Visual inspection and a tap test can be used to determine if structural damage to the pole wall laminate has occurred. If structural damage is identified or if a pole is struck by a vehicle, most often it will need replaced. Determine if a fire-resistant coating or wrap has been compromised. 59 Visual Inspection and Repair Who completes the repair? The utility company should repair the pole per the pole manufacturer’s owner’s manual. What equipment is needed? The utility company should utilize the materials recommended by the pole manufacturer’s repair method. 60 Cosmetic vs. Structural Repair Pole repair can vary slightly based on the materials used and method of manufacturing of the pole. Manufacturers provide an owner’s manual for customers, answering questions in detail. Consult the manufacturer for specific information regarding inspection & maintenance. Manufacturers may have methods of surface repair for minor abrasions and splinting systems for impacts and collisions. Surface-level cosmetic damage or shallow gouges (depending on wall thickness) can often be repaired in the field. The pole should be replaced if structural damage is identified as a crack through the side wall or extending up the pole, shearing due to impact, or is a deep gouge. 61 When to Consult the Manufacturer In situations not covered in the owner’s manual, or if the utility company has damage questions the pole’s structural integrity. When additional training or a demonstration feels beneficial. 62 Repair Steps 1. Assess 2. 3. Determine 4. 5. Repair or Perform Consult Replace Assess Perform a Determine if Consult the Repair or structural tap test repair is owner’s replace in damage structural or manual the field cosmetic or the manufacturer 63 Takeaway Inspect the damage to determine the type and extent Reference the manufacturer’s owner's manual for detailed directions and follow the instructions completely. Consult the FRP pole manufacturer in situations not covered in the owner’s manual, or if the utility company has damage questions the pole’s structural integrity. 64 Section 6: Removing 65  Removing FRP Poles When removing an FRP pole that has been damaged, take note of fiberglass particles and filaments. Particles should be swept and cleaned, and debris disposed of in a landfill. Recommended pullers include: Standard hydraulic pole puller TiiGER Pole Puller Greenlee Cable Puller Tips for removing poles: A rubber blanket can be used to increase friction between the puller and pole. If the FRP pole is to be repurposed, it is recommended to protect the pole with a piece of wood and position the chain over the rubber blanket. 66 Takeaway If pole is to be repurposed, protect the pole during removal Always use recommended equipment for cutting up poles 67 Section 7: Disposing 68 Disposal While research continues to advance in recycling of FRP materials, the most common current disposal methods are landfill and repurposing. FRP materials are inert, meaning they will not leach any chemicals or harm the environment after disposal. Many manufacturers have outlets to repurpose the poles and can provide guidance on the best option for a pole that is taken out of service. ACMA can provide a list of composites recycling companies. 69 Examples of Repurposed Poles 70 Takeaway Unlike wood, FRP poles are inert and can be landfilled. Work with the manufacturer to find outlets for repurposing poles. Poles can be upcycled, and the shape can be used for fence posts or culverts. 71 Section 8: Hands-on Field Demonstration 72 What will be learned? Safe ways to handle FRP poles Drilling, cutting, and climbing Procedure to install FRP poles Procedure to remove FRP poles Installing equipment 73  Questio ns? © 2025 American Composites Manufacturers Association (ACMA). All rights reserved. This document and its contents are the property of the American Composites Manufacturers Association (ACMA). No part of this presentation may be reproduced, distributed, or transmitted in any form or by any means, including photocopying, recording, or other electronic or mechanical methods, without the prior written permission of ACMA, except in the case of brief quotations for use in reviews or academic purposes. 74