Characterizing the performance of full-scale enhanced honeycomb sandwich composite cross-arm in transmission tower

This research addresses the critical challenges faced by transmission tower cross-arms, which endure significant bending and creep stresses over their operational lifespan, exacerbated by environmental factors that can lead to sudden failures. It is apparent that any material used in such applications is susceptible to attack from environmental factors. To mitigate these challenges a commercially available pultruded composite material, known as pultruded glass fiber reinforced polymer composite (PGFRPC) was further enhance by using a honeycomb sandwich composite structure due to its excellent structural attributes and lightweight nature. The objective of this research is to develop an enhanced pultruded glass fiber reinforced polymer composite (PGFRPC) cross-arm incorporating a honeycomb sandwich structure to improve performance and durability. A comprehensive methodology was employed, involving rigorous testing through three-point flexural deflection and creep assessments of both the existing and enhanced cross-arms, under individual and assembly conditions. The research revealed that the optimal 0° orientation angle for the facesheet made from woven glass fiber prepreg significantly improved bending properties. Utilizing the Theory of Inventive Problem Solving (TRIZ), morphological charts, and the Analytical Network Process (ANP), an optimal design for the honeycomb sandwich PGFRPC cross-arm was developed, with Concept Design 2 emerging as the top choice. The integration of the honeycomb structure on the existing cross-arm resulted in a 36.7% reduction in deflection and a 33.7% reduction in creep strain. Besides that, this research demonstrating a linear elastic behavior superior to traditional Balau wood cross-arms compared to composite cross-arm. The research also highlighted that the enhanced cross-arm's improved resistance to bending forces, creep resistance, and long-term stability could significantly extend its lifespan and reduce maintenance costs. Future research should focus on dynamic performance, flexibility reactions, failure modes, and creep analysis under normal and broken wire conditions, varying safety factors to better understand the effects of greater loads on the composite structure. Overall, this research establishes the superior creep properties of the enhanced PGFRPC cross-arm, providing valuable insights for future advancements in transmission tower technology.

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