FiberglassComponentsTF
Composites101
SteveRoberts
SouthernCompany
GalenFechtWeiChungLin JanosToth
RSTechnologiesMacleanPowerTransmissionInnovations
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FRPHistory1
DevelopmentofGlassFibreReinforced
PolymerCompositesstartedinthe1940
drivenbymainlymilitarypurposes.
In1942theU.S.Navyreplacedallelectrical
terminalboardswithfiberglassmelamine
compositeboards.
In1944thefirstairplanewithaGFRPfuselage
flownattheWrightPattersonAirForceBase.
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FRPHistory2
Polymerindustriesgrewrapidlyandtried
expandingtheirmarketusingplasticstomore
applications.Thearrivalofnew,lightweight
polymersofferedsolutionsformanydifferent
usesofferedopportunitiesincreasing
mechanicalpropertiesofplastics.
Extremelyhightheoreticalstrengthmaterials
forexampleglass werediscoveredfor
widespreaduse.
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FRPHistory3
Thefirstcompositepoleusedasa
transmissionstructurewasinstalledonthe
HawaiianislandofMauiintheearly1960s.
Thepolesweremadeoffiberglassand
replacedwoodandsteelpoles.
Thesefirstgenerationfiberreinforcedpoles
lastedabout45years.
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CurrentUse
Today,utilitiesallovertheworldareusingFRP
poles,crossarmsandothercomposite
materialsasstructuralcomponents.
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Whatisacomposite?
AccordingtoWebstersDictionary,a
compositeis:asolidmaterialwhichis
composedoftwoormoresubstanceshaving
differentphysicalcharacteristicsandinwhich
eachsubstanceretainsitsidentitywhile
contributingdesirablepropertiestothe
whole.Adobe,withmudandstraw,isan
exampleofasimplewidelyusedcomposite.
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WhatisFiberReinforcedPolymer
Composite?
Materialmadeofpolymerresinandfiber
reinforcement
Othercomponents:
1. Fillers
2. Ultra Violet (UV) inhibitors
3. Coatings
4. Other Additives
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FiberMaterials
GlassFiber(Eglass,SGlass,etc.)
CarbonFiber
BasaltFiber
AramidFiber(i.e.Kevlar)
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GlassFiber
ForTransmissionandDistributionStructures
Eglassisused
E glassdensity2.57
Ultimatetensilestrength3450MPa =500380psi
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ReasonsEGlassisUsedForT&D
Highproductionrates
Highstrength
Highstiffness
Relativelylowdensity
Nonflammable
Resistanttoheat
Goodchemicalresistance
Relativelyinsensitivetomoisture
Abletomaintainstrengthpropertiesoverawiderangeofconditions
Goodelectricalinsulation
Lowcostrelativetootherfiber options
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FiberTypes
Shortandlongfibers
Choppedstrand
Rovings
Wovenmats
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ResinSystems
Themostcommonlyusedresinsare
polyesters,epoxies,vinylesters,and
polyurethanes.
Vinylesterandpolyurethanearethetworesin
systemsthatarebeingusedforfibre
reinforcedpolymertransmissionand
distributionlinestructures.
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ResinSystems
Resinsaremajorpartoffibrereinforced
compositematerials.Dependingupon
requirements30to70%ofthevolumeofa
compositecouldberesin.
Therearetwomajorclassesofresins:
1.Thermoplastics
2.Thermosets
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ThermoplasticResin
Thermoplasticorthermosofteningresinisa
polymerthatremainssolidatroom
temperature,itsoftensandmeltsathigher
temperatureandbecomepliableor
mouldableandsolidifiesasbeingcooled
down.
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ThermosetResin
Thermosettingresinorbyothernamethermosetwillcure
permanentlybyirreversiblecrosslinking.
Oncehardenedathermosetresincannotbereheatedand
meltedtobeshapeddifferently.Thischaracteristicmakesthe
thermosetresincompositesverydesirableforstructural
applications.
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ThermosetVinylEster
ResinSystem
VinylEster,orVinylester,isaresinproduced
bytheprocesscalledesterificationofan
epoxyresinwithanunsaturated
monocarboxylicacid.
Acompositeproductcontainingavinylester
resincanwithstandhightoughnessdemand
andofferexcellentcorrosionresistance.
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ThermosetPolyurethaneResin
Systems
Workingwithpolyurethanesystemrequires
significantlybettercontrolofthe
manufacturingprocess.
Theresultingproducthassuperiorproperties
andmakesitpossiblecreatinglightdurable
andstiffstructuralcomponentsfor
transmissionlineapplications.
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Fillers
Fillersintheresincanchangeviscosity
(thickeningtheresin)andchangethefinal
propertiesofthematerialmatrixsuchas
abrasiveresistance,color,density,
machinability,smoothnessandstrength.
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Additives
Therearethreegroupsofadditives.
1. Catalysts, promoters and inhibitors
2. Pigments
3. Releasing agents
Theirnamesverymuchdescribetheirroles.
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Inhibitors:UVLightInhibitors
Ultraviolet(UV)lightinhibitorsareusedin
fibrereinforcedpolymerapplicationsto
preventandimpededegradationofmaterial
causedbyUVrays.Theycouldbepartofthe
resinorcouldbeappliedasseparatecoating.
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Inhibitor:FireRetardant
Fireretardantsareadditivesthatisaddedto
theresinimprovingitsresiliencyagainstfire
andhightemperature.Forexample,Antimony
Trioxideisoneofthemostwidelyusedflame
retardants.
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ManufacturingProcessesforFRP
Components
Pultrusion
Filamentwinding
Bladdermoulding
Compressionmolding
Vacuummolding
Mandrelwrapping
Wetlayup
Choppergun
Resininfusionresintransfermolding (RTM)
Vacuumassistedresintransfermolding (VARTM)
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Pultrusion
Constantdiameter
Cuttolength(canbespliced)
Longitudinal/axialfiberplacement
Continuousstrandmat
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FilamentWinding
Tapered
Setlength singlepieceormodular(canbestackable)
Circumferentialrovingwraps
Longitudinal/axialfiberplacement
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CostingforFRPComponents
Materialcostcanbeequaltoorgreaterthan
traditionalmaterials
FRPcharacteristicsenablelowerinstalled
costs
Duetolongservicelifeandlowmaintenance
requirements,lifecyclecostingisthelowest
withFRPcomponents
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LifeCycleCostComparison
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CostingEvaluationforFRP
Components
Inwhatapplicationsismytraditionalgrid
infrastructurenotachievingfullservicelife?
Whatinstallationshaveahighercost?
UsinghighperformanceFRPcomponents
lowercostsvirtuallyimmediately
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EnvironmentalBenefits
Inertcompositematerialwillnotleachharmfulchemicals
Nosoilremediationordisposalcosts
Nopreservativetreatmentsrequired
Safeinstallationinenvironmentallysensitiveareas
Recyclable,upcyclable ordisposalinlandfill
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FirePerformance
FRPcompositematerialsareselfextinguishingand
donotsupportcombustion
Ifaconstantflameisheldonthesurfacetherewill
besomecharringandmaterialloss
Commonly,anystrengthlossisstillwithinthe5%LEL
publishedvalues
Fireretardantadditivescanfurtherimprovefire
performance
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StrengthCharacteristics
Highestspecificstrengthofanypolematerial
Highelasticstrainenergyabsorption
Cantypicallyachieve23xdesignloadandremainin
linearelasticrangewithoutcatastrophicfailure
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ComparisonofFRPStructures
230 kV H-Frame Structure Component Weights
StrengthEquivalency
Manyengineeredmaterialsarecomparedtowoodpole
equivalents(WPE)
BasedonANSIO5.1loadings
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ServiceabilityEquivalency
Stiffnessratioofcompositecomponentscanbeless
thantraditionalmaterials
Considerationneedstobegiventodeflection
ASCEhasdevelopedwoodpoledeflectiontablesasa
deflectionreference
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FRPCrossArms1
FRPCrossArmwithBracing
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FiberglassProducts Brackets
EquipmentMounts
HoldsupequipmentlikeArresters,cutouts,postinsulators,and
terminations
0and15degree
1,2,and3phase
Single,double,andtripleear
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FiberglassProducts Brackets
Pintype
Holdspininsulators,usedfor
armlessconstruction
15degreeandridgepins
1,2and3phase
Verticalandhorizontalthreadsinplastisol,nylon,orleadthread
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FiberglassProducts Brackets
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FRPCrossArmsforHFrames
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FRPCrossArmsforHframes
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FullFRPHframe
FRP Cross Arm
FRP Cross Bracing
FRP Pole
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FRPDistributionStructure
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FRPSwitchingStructure
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FRPAnchors
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FRPAnchors
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FRPGrillageFoundation
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FRPLatticeStructures
More designs in development
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FRPSheetPiles
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ModularPoles
Standardsizedmodulesareusedto
createcustomlengthandstrength
poles
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ModularPoles
Atadiscreetlength,differentpolediametersresult
indifferentstrengthpoles
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ModularPoles
Wallthicknessvariationsfurtheroptimizepoleson
astrengthandcostbasis
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DistributionPoles
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TransmissionPoles
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Questions?
SteveRoberts
SouthernCompany
SERobert@SouthernCo.com