How composites are modernizing the electrical industry
ELECTRICAL & ELECTRONICS REINVENTING THE POWER GRID
EXEL COMPOSITES
How composites are modernizing the electrical industry
The electrical industry is facing pressure, with aging infrastructure and growing electricity demand. At the same time, traditional materials such as wood, steel, and porcelain increasingly reveal limitations, pushing design engineers to search for replacement solutions. Composite materials are not only an alternative to convention, but an enabler of more resilient and efficient electrical systems. Here, Mika Kepponen, product manager at composite manufacturing specialist Exel Composites, explores the possibilities of composites within electrical applications.
Modern electrical infrastructure relies on materials capable of sustaining mechanical integrity and electrical properties over long service lives, even in harsh and highstress environments. Composite materials are transforming the electrical sector by integrating high mechanical performance and reliable electrical properties into one-high performance profile.
Composites in electrical distribution and transmission must meet strict mechanical strength, dielectric performance, weathering resistance, and safety standards such as IEC, IEEE, and ASTM requirements to ensure long‐term reliability in high‐voltage environments.
Utility poles: a case study in infrastructure modernization
Several areas of composites production facilitate better personalization for utility infrastructure. Careful resin selection enhances insulation, while precise fiber placement increases profile strength, allowing components to be tailored to exact specifications.
Mika Kepponen, product manager at Exel Composites
Whether electrical or transportation, the demands on decades-old infrastructure continues to grow.
In the United States, for example, approximately 185 million utility poles carry electrical lines across urban and rural areas, yet around 2.5 million wooden poles must be replaced annually due to damage, rot, or aging.
As noted by Dan Coughlin, the vice president for the American Composites Manufacturers Association:“ These outages immediately halt economic activity through the loss of mass transit, traffic lights, electronic tolling stations, and retail cash registers. They also raise recovery costs related to mobilization, backup power provision, and temporary housing,” highlighting the economic impact of aging pole infrastructure.
Decay and aging are common, but wooden utility poles also suffer damage from weather events, particularly high-impact winds. In comparison, composite utility poles have higher environmental resistance. In utility pole production, filament winding techniques produce transverse fiber orientations, increasing poles’ rigidity and reducing wind deflection.
Composite utility poles can last up to 80 years, around double the lifespan of wooden poles. Increased service life reduces the need for replacements or repairs, reducing maintenance costs. Additionally, composite poles are lightweight and easier to install, minimizing risks of accidents or injury to engineers.
Improving safety with composite insulators
Insulator rods are one of the most important and widely used products in electrical transmission and distribution. Forming a structural and insulating core, composite insulators support conductors and maintain electrical separation from towers, poles, and crossarms. Their lightweight advantage reduces load on supporting structures, enabling easier transportation and installation as well as increased design flexibility without compromising performance.
Among safety concerns for engineers, porcelain insulators can rupture or explode under
62 PECM Issue 79