Hybrid steel–composite cross-arm for distribution power lines

This paper describes the development of electrically insulating hybrid steel–composite cross-arm for medium-voltage overhead distribution power lines with three conductors. The main goal was to achieve substantial weight savings compared to a common steel cross-arm with three ceramic insulators widely used in the Czech Republic. The structure has been designed as a combination of two main composite components – a pultruded horizontal profile and a braided vertical conical tube. These components are connected by a steel locking component which also serves for attaching the whole cross-arm to common concrete utility poles. The hybrid cross-arm is conceived to insulate electrical current in the default configuration thanks to the properties of the glass fiber reinforced composite materials, yet additional insulating elements can be used to further increase the electrical insulation distance. The materials and components used for the construction are chosen by combining finite element simulations of mechanical and electrical behavior with experimental testing and verification of important characteristics on selected substructures. The final design of the cross-arm is then manufactured and subjected to long-term testing in real-life environmental conditions. The achieved reduction of weight exceeds 50% while maintaining the mechanical rigidity and strength of the steel solution as well as the required insulation properties. The future trend of the cross-arm development is aiming at the weight reduction and increase of manipulation capabilities resulting in lowering many additional costs. In this work the designed cross-arm has half the weight of the original one.