Throughout my 40-year career as a lineman in the transmission and distribution industry, I have seen many new innovations. With these innovations come more choices as well as the questions and concerns the line workers have about working with the new products. Steel distribution poles are a good example. When I first started seeing steel poles being used for distribution lines, I had my doubts. But as I learned more about how to handle them and their benefits, I became a believer.

A survey by the American Iron and Steel Institute (AISI) found that at least 600 of the 3100 electric utility companies in the United States now use steel poles in their distribution systems. Some utilities have even converted entirely to steel poles, a decision based in large part on the recommendations of their linemen who work with the steel poles every day.

This broader acceptance of steel poles creates a challenge for experienced line workers who are faced with trying to stay on top of the new equipment available, both to make good choices and to maintain proper procedures when working around them.

I can personally attest to this challenge. As a line worker and later as a safety and training instructor, I have seen every type of transmission and distribution structure imaginable — wood, concrete, metal, round, square, lattice — and I have worked with them all. When I first started working with steel poles, I had to ask many questions about the differences between wood and steel and the characteristics of each.

These experiences have been invaluable at Omaha Metropolitan Community College (OMCC), where I have been the line tech trainer since 1991. What I saw was a need for hands-on training in steel-pole essentials not only for experienced line workers, but also for new line technicians getting into the utility business.

New Training Program

Last year I decided to put my experiences and those of other linemen together to create a nuts-and-bolts training program on steel distribution poles. I teamed up with AISI, Valmont Industries, Thomas and Betts Corp. and the American Zinc Association to create an intensive one-day training program designed specifically for students studying to become linemen. We launched the first one-day intensive training class at the OMCC in May 2005.

Based not only on my field experience but also on our research in the industry, the workshop format is designed to provide relevant and useful hands-on training in the basics of working with steel distribution poles — drilling, installing and climbing. I saw the need to create a workshop curriculum that familiarizes students with steel, giving them a basic understanding of the general characteristics of working with steel poles. Students in the class have the opportunity to work with instructors and fellow students to gather feedback and useful tips for working with steel.

Please understand that a lot can be said about wood poles. They are the backbone of our nation's distribution system and will continue to make up a large portion of the pole population. Line workers already have a wealth of knowledge and experience in working with wood poles, and there are many outstanding wood-pole training programs available. But what I saw was a need to provide some training when working around steel poles.

Steel Basics

In my speaking engagements and in the classroom, some of the most commonly asked questions are about the physical characteristics, climbing, safety, cost and the life cycle of steel distribution poles.

The average steel distribution pole (40 ft, Class 4) weighs approximately 30% less than wood poles, which make them easy to work with and handle. Steel poles weigh approximately 450 lbs, depending on their size, and longer poles are sectional, with each running 25 ft to 55 ft long. Because of the material, manufacturers often externally finish the pole to a variety of appearances, including specific colors and nonglare finishes.

Many linemen ask about climbing steel poles. They are made easy to climb with pole steps, which are easily installed depending on the structure and may include a platform to work on, if necessary. Steel poles don't rot, splinter or crack, so the risk associated with climbing a bad wood pole are eliminated, which is a climbing advantage and a safety benefit.

When we talk about line-worker safety, I also like to point out that steel poles don't catch on fire, so there is no chance of ground or pole top fires. Furthermore, there is no need for preventive (wood) pole treatment, which means there is no risk of exposure to toxic chemicals or special handling requirements either during installation, maintenance or removal.

The Cost Factors

Students often ask about the long-term cost of steel poles versus the tried-and-true wood poles. There are several factors to consider when calculating the cost. When engineering specifications are compared equally, the initial cost of a steel pole can be competitive with that of a wood pole.

Because steel is lighter than wood, they cost less to ship and they require less expensive equipment to handle and install. No special hardware is needed to install steel poles, although a nylon sling instead of a chain is suggested for unloading and setting. Steel can be predrilled, which also reduces labor time during field installation. Because they are self-conductoring, installing a full-length copper ground wire is eliminated, which again reduces the material and installation costs.

As I mentioned, steel poles do not rot; therefore, the life span of a steel pole can exceed 60 years, providing a lower life-cycle cost. Steel also doesn't shrink with age, decreasing the need to periodically tighten hardware and drill new holes. And there is no need for woodpecker and other intrusive animal inspections. Over the years, I have observed that steel poles do not break off as easily when involved in a car accident, and as they have become more prevalent in the distribution industry, I have been able to observe that they suffer less damage in bad storms. Steel is also much more available and requires no preshipment inspection, further reducing costs.

We're Training for the Future

With a year under our belt, the line tech training program is spreading quickly across the country. Kansas, Arizona, Colorado and Georgia are just a few states that have offered the steel pole training workshop. The feedback on the new curriculum has been extremely positive. We are looking forward to even more workshops in 2007 and the opportunity to work with other aspiring linemen.

To reach more line tech students, as well as utility line workers already on the job, we are developing “train-the-trainer” curriculum and educational materials to help college and corporate instructors understand and become skilled at teaching about steel poles. They will have access to an instructional DVD and, in the future, an instructor's web page, where they can observe me or my co-teacher Rich Newcomer in a training session.

With these new programs, I hope we are doing our part to further the line technician's education and, on a more global scale, helping to support the reliability of our nation's power transmission and distribution system.

---

Gary McDonald is a 40-year veteran, having worked as a journeyman lineman for Omaha Public Power District, Sacramento Utilities and Utah Power and Light. In 1991, when McDonald joined Omaha's Metropolitan Community College, he created the utility line technician program, which he taught for nine years and was the job training and safety coordinator for the Nebraska Rural Electric Association. McDonald continues to serve as a consultant to a variety of organizations in the power transmission and distribution industry. gspringer@huntel.net