What Every Lineman Should Know - American Iron and Steel .../media/Files/SMDI/Construction/UPoles -...

A M E R I C A N I R O N A N D S T E E L I N S T I T U T E

SStteeeell DDiissttrriibbuuttiioonn PPoolleess:: What Every Lineman Should Know

Instructor Manual

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Steel Distribution Poles: What Every Lineman Should Know!

Steel Distribution Pole Disclaimer

The material presented in the DVD and accompanying electronic and written presentations has been developed by a joint effort of the American Iron and Steel Institute, Omaha Metropolitan Community College, and EDM International, Inc. These organizations have made a diligent effort to present accurate, reliable, and useful information regarding the use of steel distribution poles.

We believe that the material presented in the DVD and accompanying electronic and written presentations reasonably reflects the present state of knowledge as to the subject, as it is generally known, but we do not warrant this or claim that such material is entirely accurate or complete. And we do not accept any obligation to issue supplements to or corrections or the material in the event of errors being discovered or advances being made in the techniques discussed in the material. Thus, all users of the material should have the assistance of, and rely on, their own experts in the design, construction and maintenance of steel distribution poles

The material presented in the DVD and accompanying electronic and written presentations are for general information only. It is not a substitute for competent professional advice. Persons making use of the information set forth herein do so at their own risk and assume any and all liability arising therefrom.

Instructor Manual


TABLE OF CONTENTS TABLE OF CONTENTS ................................................................................................... i INSTRUCTOR PREPARATION ...................................................................................... 2

Program Material ......................................................................................................................2 Review Materials.......................................................................................................................2 Facilities and Equipment ...........................................................................................................3 Course Introduction...................................................................................................................3

PART 1: STEEL POLE BASICS..................................................................................... 4 Course Outline ..........................................................................................................................4 Teaching Emphasis ..................................................................................................................4 Introduction ...............................................................................................................................5

Why use Steel Poles .............................................................................................................5 Steel Poles are a Manufactured Product ..............................................................................5

Steel Pole Applications .............................................................................................................5 Shipping and Handling of Steel Poles.......................................................................................6

Protective Coatings...................................................................................................................6 Review Questions - First Half of Session..................................................................................7 Line Construction ......................................................................................................................7

Bolt Tightening ......................................................................................................................8 Hole Drilling...........................................................................................................................8 Structure Assembly ...............................................................................................................8 Foundations ..........................................................................................................................8 Arms and Hardware ..............................................................................................................8

Line Operations.........................................................................................................................9 BIL.........................................................................................................................................9 Grounding .............................................................................................................................9 Working Around Energized Lines..........................................................................................9Climbing ................................................................................................................................9

Review Questions – Second Half of Session..........................................................................10 PARTICIPANT’S QUIZ.................................................................................................. 11 PART 2: FIELD DEMONSTRATION ............................................................................ 14

Field Exercises........................................................................................................................14 1. Hole Drilling Techniques .................................................................................................14 2. Arm Framing ...................................................................................................................14 3. Pole Assembly ................................................................................................................14 4. Pole Erection...................................................................................................................15 5. Setting and Backfilling.....................................................................................................15 6. Climbing ..........................................................................................................................15

Materials and Equipment ........................................................................................................16

Instructor Manual Page -i-


INSTRUCTOR PREPARATION

Program Material

This program consists of the Instructor Manual, Student Manual, and a DVD and/or Microsoft PowerPoint™ presentation. A copy of the Student Manual should be made for each participant in the course. If you have questions regarding the materials or content of this program, please contact the American Iron and Steel Institute

Call – (202) 452-7100, Email – [email protected], or Visit – www.steel.org

Review Materials Both a DVD and a PowerPoint presentation are available for use in conducting this session; either one or a combination of the two may be used. The DVD runs for approximately 25½ minutes, and will be the most practical presentation when classroom time is limited or when the instructor is not very familiar with the material. The DVD also provides for some good movie footage, which is helpful in illustrating several points regarding steel poles . The PowerPoint presentation is designed to be used by an instructor who is knowledgeable about the use of steel poles. The primary advantage of using the PowerPoint presentation is that it allows students to ask questions at any point during the presentation rather than having to wait until the end. The PowerPoint slides require more time for presentation; a minimum of 1½ - 2 hours of classroom time is normally needed when using this presentation format. It is recommended that as an instructor you review the content of both media. You may decide that using a combination of the two will provide the most meaningful learning experience for your student audience. Following completion of your presentation of the material, a quiz should be given. The quiz is included in the Student Manual. This quiz should only take ten to fifteen minutes to complete and then another 20-30 minutes to review the answers. Each participant should be allowed to “grade” his/her own answers. Make this an interactive session by asking the participants to volunteer their answers. When there is confusion over the “correct” answer, further discussion of that point is warranted. The last two questions are important and are sure to generate discussion among the participants. They will also provide valuable feedback to the instructor and to AISI.

SSTTEEEELL DDIISSTTRRIIBBUUTTIIOONN PPOOLLEESS:: What Every Lineman Should Know

Instructor Manual Page - 2

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Facilities and Equipment

The classroom facility requirements for this course are not extensive. Each student should have a table and chair to facilitate note taking during the program. To promote interaction among the students, set up the room in a semi-circle or hollow square so that the students can all see the instructor, the screen and each other, where possible.

The following equipment will be needed to teach Part 1 (Classroom Session) of this course: DVD player and/or computer and LCD projector Video monitor(s) large enough for all the students to view (the larger the better) Pens or pencils for students to take notes in their manuals

Other materials that may be helpful in conducting the classroom session include: Flipchart and/or white board with markers and eraser Equipment to be used in Field Demonstration (e.g. pole steps, drill bits, nylon sling, etc.)

The materials and equipment needed to teach Part 2 (Field Demonstration) are listed on page 16.

Course Introduction

During the program introduction, provide students with an overview of the program and establish a comfortable tone:

Provide an overview of your expectations for the class as well as the materials, quiz and course schedule.

Outline when breaks and lunch will occur. If you do provide an exact time for those breaks, be sure to break at that time. You may wish to simply state that breaks will occur at certain points throughout the program and not provide an exact time.

Tell the students how long the program is expected to take and be sure to stick to that timeframe.

Provide details regarding bathroom and refreshments/vending machine locations, etc.

Explain that students will receive recognition for successfully completing the program and what the recognition will be (Certificates of Completion, etc.).

Begin the program by asking each student to introduce themselves, especially if you have students from various companies or even departments.



PART 1: STEEL POLE BASICS

Course Outline Following is the course outline that will be used to cover this classroom session on Steel Pole Basics. The PowerPoint slide numbers and DVD time segments that pertain to each section of the presentation are noted in parentheses:

Introduction: Slides 1-4; DVD 0:00-3:38 Steel Pole Applications: Slides 5-8; DVD 3:39-4:10 Shipping and Handling: Slides 9-13; DVD 4:11-6:24 Protective Coatings: Slides 14-17; DVD 6:25-11:06 Line Construction: Slides 18-25; DVD 11:07-18:57 Line Operations: Slides 26-33; DVD 18:58-25:30

Teaching Emphasis This course is designed to teach Operations and Line Personnel about steel poles. It covers all the aspects of steel poles that are important to the people who have to physically handle and work these poles. The material should be presented in a manner that provides an opportunity for the students to ask questions and exchange ideas. The Student Manual provides all of the information that the AISI believes Line Workers need to know to properly and safely work around or on steel poles. There are certain points that should be emphasized when the material is presented. As an aid to the instructor, these points are provided are outlined herein alongside the PowerPoint graphic that deals with the topic.



Introduction Why use Steel Poles? The following are a few of the more important benefits that steel distribution poles have to offer:

Steel poles do not vary in dimension. Steel poles are at least 30% lighter than a wood pole of similar strength.

Steel poles can be made to handle virtually any load and in any length and can also be made as single piece poles or in sections if that would help handling them in the field.

Steel Poles are a Manufactured Product Most distribution poles are shorter than 55 feet. They can be made as single piece poles with a maximum length of 55 feet or, if needed, they can also be made as multi-piece poles to make their storage, transport or erection simpler.

Steel Pole Applications Steel poles are used in much the same way as wood poles. They are normally direct embedded to the same depth and are framed very similarly. Also, when loaded they do not deflect as much as wood poles. Steel poles have become especially popular in deadend situations. These applications can be met with either a guyed pole, such as is normally used in wood construction, or with a freestanding pole when guys are impractical to use. As a guyed pole, steel poles are typically stronger than their wood pole counterparts. Remote distribution line locations are also idea for steel poles, which typically require less maintenance than wood pole installations.



Shipping and Handling of Steel Poles Because they are lighter than wood poles, more steel poles can be loaded on a trailer making their transport more efficient. Steel poles are hauled to the site very much like wood poles

Steel poles can be lifted using a single-point pick up. Because they are lighter, the boom can be further out which can be advantageous in situations where the truck has to be away from the foundation hole. Steel poles should be handled with nylon straps or rope as opposed to chain or steel cable to protect the finish from damage. Where pole site cannot be accessed by truck, a steel pole can actually be hand-carried into the site.

There is no need to rotate steel poles in storage.

Protective Coatings There are several ways to protect steel distribution poles, both above and below ground. Galvanizing is probably the most popular of all the systems used. It provides cathodic protection to the steel, which means that the zinc coating acts as a sacrificial barrier to protect the steel. The zinc coating is relatively hard and will stand up to normal handling without being damaged. It is also durable and will last for many years before any recoating is required. Forty years or more is not an uncommon life expectancy for a galvanized coating.



Behind galvanizing, weathering steel is probably the most popular choice as a protective coating although weathering steel is not so much a coating as it is chemistry. Except for weathering steel, all these systems use zinc in some form to provide cathodic protection. Zinc by itself, however, does not always provide the necessary protection. In harsh environments where there is a lot of moisture mixed with pollutants such as salts, the zinc can be consumed quickly leaving the steel unprotected. In these situations, it is recommended to use a protective polymer coating at and below the ground line. Soils can be very corrosive and the below ground area is often the harshest environment for the steel.

Review Questions - First Half of Session This is the approximate midpoint of the presentation and a good time to review the material that has just been covered. Following are some suggested questions that can be asked: 1. Name the five primary types of systems that are used to protect the steel from corrosion.

A: Galvanizing, Metalizing, Zinc-silicate, Paint and Weathering Steel

2. All steel poles are made recycled materials. A: True (Each steel pole contains at least 25% recycled content).

3. True or False – When hauling, you can typically place more steel poles than wood poles on the trailer. A: True (Typical load sizes range from 20-30 poles).

4. True or False – Like wood poles, steel poles should be rotated when in storage for a long period of time. A: False.

5. True or False – A protecting barrier coating should be applied to the below-ground portion of a weathering steel pole. A: True.

Line Construction There are some distinct differences between wood and steel poles: Wood poles are solid and steel poles are hollow, Steel poles have very consistent dimensions while wood poles

can vary in diameter considerably, and A steel pole’s geometry will not vary with the seasons, while wood

poles will shrink and expand, twist and check as the climate changes. Such movement can often cause hardware on wood poles to loosen, creating the need to retighten the hardware periodically. This is not the case for steel poles, which means less routine maintenance and more time saved.



Bolt Tightening With steel poles it is often sufficient to tighten the nuts just beyond snug tight.

Hole Drilling The field-drilling of holes is relatively easy if you have the right tools. Holes in thinner steel (i.e. steel thickness ~ 3/16-in. or less) can be drilled in 30 seconds or less with a hand-held, battery-powered drill using a stepped or “Christmas tree” bit. To drill through holes in poles with thicker walls, you can use a magnetic drill with a hole saw to make the job easier.

Structure Assembly It is no more difficult to frame a steel pole than a wood pole and it can sometimes be easier. In the case of multi-piece poles, slip joints are the most common means of fitting the sections together. A slip joint is a simple friction fit connection where the top section is slipped over the bottom section until tight fit and minimum lap is achieved with no significant gaps between the sections.

Foundations You can direct embed steel poles the same as you can wood poles and you can use the same type of backfill material (e.g. native soil, crushed rock, etc.) And, where direct embedment is not practical, base plates can be welded to the bottom of steel poles so that they can be mounted on anchor bolts that are either set into concrete foundations or grouted directly onto rock.

Arms and Hardware All types of arms (steel, fiberglass (FRP) or wood) can be used on steel poles and these arms are often attached to the pole in the same manner as on wood poles.



Line Operations BIL BIL is the measure of a structure’s insulation ability to withstand a voltage spike, such as from a lightning strike. A Basic Impulse Level (BIL), also referred to as Basic Insulation Level, for line construction is not something that the Safety Code prescribes but 300kV is a

level that many utilities consider minimum.

Grounding Good grounding is essential to system reliability and safety. Steel poles are an excellent conductor and can easily provide a good ground at very pole, if desired.

Working Around Energized Lines When working around live lines, all materials need to be treated as if they are conductive and the standard approved work practices of the utility need to be followed. Such procedures almost always include:

Set and tag reclosers in the non-reclose position Use a dedicated observer and signal person Cover live conductors Use cover-ups or guards on the pole

Climbing Most utilities have adopted some type of step (or ladder) system for use on their steel poles and removable steps seem to be the most common.



Work Platforms There are times when working off of steps or ladders may be awkward. A few utilities have addressed this problem by designing a simple work platform that can be easily placed at most any location along the pole.

Review Questions – Second Half of Session This is the end of the classroom presentation and a good time to review the material that was covered in the second half. To review the material covered in this portion, following are some suggested questions that can be asked: 1. True or False – Slip joints need to be bolted together after they are fully assembled. A: False.

Slip joints are generally designed to be friction connections and do not need to be bolted together unless specified by the pole manufacturer.

2. True or False – Direct embedded steel poles by themselves always provide good grounding. A: False. If the embedded portion of the pole is fully coated with something other than zinc, the coating will act as an insulator and a ground rod will need to be installed.

3. True or False – Steel poles can only be accessed with a bucket truck. A: False. Most utilities have adopted some type of step system, commonly removable steps, on their poles.

4. True or False – Special backfill material should be used when embedding a steel pole. A: False. Steel poles can typically be embedded the same way as wood poles are embedded.

5. True or False – When installing steel poles in or near an energized line, different work practices are needed than those used when installing wood poles. A: False. All poles need to be treated as if they are conductive. Thus, the same work practices should be used for both.



PARTICIPANT’S QUIZ (Instructor’s Edition)

NOTE TO INSTRUCTOR: This quiz should only take ten to fifteen minutes to complete. It is recommended that time be allotted to give it at the conclusion of the workshop and then spend 20-30 minutes reviewing the answers. Each participant should be allowed to “grade” his/her own answers. Make this an interactive session by asking the participants to volunteer their answers. Where some are confused by the “correct” answer, there can further discussion of that point. The last two questions are important and are sure to generate discussion among the participants. They will also provide valuable feedback to the instructor and to AISI. The following questions are being asked to help you discover how much you learned by participating in this workshop. Please take a few minutes to read and answer them, then we will discuss each question and answer. 1) Which of the following applications are suitable for steel pole usage? (circle all that apply)

a. Tangent structure b. Deadend/Angle structure c. Guyed structure d. H-Frame structure Steel poles can be used in any application where wood can be used

2) What percentage of a steel pole can be recycled at the end of its service life? a. Cannot be recycled b. 25% c. 50% d. 100%

3) True – or – False (circle one): When used as an angle or corner structure, a steel pole always needs to be guyed, as does a wood pole.

Steel poles are available in strengths that exceed the capacity of wood poles and thus can be used as un-guyed corner structures if desired

4) What is the most popular protective coating system for steel distribution poles?

a. Hot-dipped galvanizing b. Zinc silicate c. Metalizing d. Paint e. Self-weathering steel Overall, hot-dipped galvanizing has been the most popular coating with weathering steel being second. However, a single utility may elect any one of these coatings as its standard.

5) Galvanized poles are typically furnished as single piece poles, with a maximum length of…

a. 35-ft b. 45-ft c. 55-ft d. 70-ft Most manufacturers can make 55-ft pole sections without needing to use circumferential welds and most galvanizers have tanks that can handle poles of this length.



6) While in storage, how often do steel poles need to be rotated?

a. Monthly b. Every three months c. Every six months d. Rotating is not required Unlike wood poles that are treated with oil-borne preservatives that tend to migrate to the bottom of the pole, steel poles do not need to be rotated while lying in storage.

7) True – or – False (circle one): If a pole is galvanized, no additional coating is ever needed on the embedded portion of the pole.

Some soil conditions are harsh enough that some type of barrier coating over the galvanizing is needed to keep the zinc from being consumed too quickly.

8) Name the two basic types of field joints that are used to connect the sections of a multi-piece pole: Slip Joint Flange Joint 9) Name the three primary ways of making attachments to a steel pole: Through-bolting Pole bands Welded attachments 10) Holes should only be made in a steel pole using which of the following

a. Stepped or “Christmas tree” bit b. Twist bit c. Hole Saw d. Any of the above Some may be easier and/or faster to use than others, but any method can be used satisfactorily.

11) Which of the following crossarms is best suited for steel pole construction? a. Wood b. Steel c. Fiberglass d. Any of the above Any of these types of crossarms can be used on steel poles, although fiberglass arms are gaining in popularity.

12) According to a study by NEETRAC, in single-phase construction, a fiberglass poletop pin of what length should be used?

a. 9”-10” b. 13”-14” c. 18”-20” d. A fiberglass spin should not be used The pole manufacturer will sometimes specify a torque value to use for tightening connection bolts. Lacking this, snug tight is generally deemed to be sufficient.



13) What is the most common means for climbing a steel pole?

a. Removable ladders b. Permanent ladders c. Removable steps d. Step bolts Most utilities use some type of removable step, which mounts in a hole in the pole, for climbing. However, any single utility may decide to do something different.

14) List three things about steel poles that you see as the primary advantages over wood poles.

There is no one set of correct answers here. The purpose of this question is to get the participants to think about what they have learned and to voice what they see as advantages and create some dialogue between them. Possible answers include: Lighter weight, Dimensional consistency (knowledge that hardware will fit), Dimensional stability (hardware won’t loosen due to pole’s shrinking and swelling), Strength consistency pole-to-pole, Large range of available strength classes and pole lengths, Choice of coating/color, Made from recyclable material.

15) What is the biggest disadvantage you see you see in using steel poles vs. wood poles?

There is no one correct answer here. The purpose of this question is to get the participants to voice what their biggest hang-ups are over using steel poles so that they can be addressed before leaving the workshop. Often times, other participants will not see the voiced concerns as problems because they see the solution and will share their points of view which will foster a spirit of making steel poles work for them.



PART 2: FIELD DEMONSTRATION The Field Demonstration session is designed to provide the students with first-hand experience in working with steel poles. As much as possible, the students should be given “hands-on” participation opportunities.

Field Exercises This session is made up of several different exercises. Ideally, all of the exercises should be scheduled. However, the instructor will need to determine beforehand which ones can be accomplished within the time allotted and the material and equipment available. Following is a list of the exercises that are recommended along with a few suggestions about what should be covered in each:

1. Hole drilling techniques: Since the equipment is different for drilling holes in steel poles than that used for wood poles, it will be helpful for the students to gain a feel for how simply holes can be drilled in a steel pole. Most line trucks are equipped with a generator that can be used to power an electric drill. However, a fully-charged battery-powered drill can also be used. Using both will demonstrate the difference in proficiency between the two. Another tool that can be used is a magnetic-base drill. This tool can make the job easier even easier if many holes need to be drilled in the field and/or if the plate is much thicker than 3/16-inch. If possible, have both a hole saw and a step-bit available to use with these drills. Most framing attachments require through-bolting. Because steel poles are hollow, this means that two holes need to be drilled 180º apart. Demonstrate how the position of the second hole can be easily located by using a string to wrap the circumference of the pole at the hole location and then using the mid-point of the string to locate the point opposite the first hole.

2. Arm framing: Framing an arm to a steel pole is very similar to framing an arm to a wood pole, except - “Cleated” gains need not be used. Flat or curved washers are typically substituted for these gains. Also, it is generally acceptable to use lock washers in lieu of lock nuts on the bolts. Bolt tightening is usually done by turning the nut until it is snug tight and then adding another ½ to ¾ turn. (Note, if significant pole ovalizing is noted, then the nut should be backed off slightly.)

3. Pole assembly (multi-piece pole with a slip joint): Poles can be assembled either while cribbed in a horizontal position prior to pole erection or during the erection process. In either case it is important that the pole manufacturer’s assembly requirements be met. This generally includes Achieving a minimum length overlap, Having no significant gaps between the lapped sections, and



Applying a minimum amount of force when assembling the mating sections. (This can often be achieved by using a slip-joint jack, come-alongs, or possibly using the truck’s boom to exert downward force on the upper pole section when using the aerial assembly method.)

4. Pole erection: Because steel poles are typically at least 30 percent lighter that their wood pole

counterparts, they are easier to lift. This means that the boom of the truck can be at a lower angle if necessary.

A single point pick is appropriate with the pick point being some distance above the center of gravity of the framed pole.

Nylon slings (not chain or wire rope) should be used in choker fashion when moving and setting the pole (note, a double wrap of the sling will provide additional safety).

If a multi-piece pole is being picked up then the sections need to be “tied together” until after the pole is set to prevent the slip joint from coming apart.

During this exercise is a good time to discuss the setting of steel poles in or near an energized line, which is often a point of resistance among line workers. It is important to stress that all poles, regardless of their material, are required to be treated as if they are conductive. Thus, the same procedures need to be used for setting both wood and steel poles. If safe work practices are followed, then there is no more risk associated with setting steel poles as there is with setting wood poles.

5. Setting and backfilling: The steel pole should be set in the augered hole using the same practice as used with wood poles. A plumb bob can be used for ensuring the pole is set in a true vertical position. If only the base of a multi-piece pole is to be set, caution needs to be exercised to ensure that it is turned to the correct orientation so that when the pole top is set, the arms will be in the proper position. Backfilling around a steel pole uses the same basic technique as backfilling around a wood pole. Typically the excavated material is put back into the hole in lifts and then tamped. If the soil is dry, water may need to be added to the hole. (Note, the coating on the embedded portion of the pole will withstand a certain amount of abuse from the tamper, but some caution needs to be exercised to not beat the pole to the point of abrading the coating.)

6. Climbing: While most line operations are conducted from bucket trucks today, there is still the occasional need to climb a pole. This exercise will provide the students with first-hand experience in climbing steel poles. Provide hands-on practice to students in the proper installation of the utility’s chosen climbing system for its steel poles. Explain proper positioning for working aloft and where possible allow a student to drill a hole for a new step to create a more comfortable/balanced work posture.



If work platforms are available for use, demonstrate their proper installation and use.

Materials and Equipment In preparation for this session the following materials and equipment need to be available at the training site:

1. Steel pole*: If sectional poles will be used in practice, then a two-piece pole should be used so that slip-joint assembly can be demonstrated (note – if a sectional pole is used, then a copy of pole manufacturer’s recommended assembly instructions should be available along with the necessary assembly equipment – e.g. jacks or come-alongs)

2. Line truck with drilling auger and setting boom: To save time, the foundation hole for setting the pole may be augered prior to students’ arrival (this operation is no different than what would be used when installing a wood pole)

3. Crossarm and framing hardware: Use arm type (FRP, wood or steel) and connection hardware that is planned for use with the utility’s steel pole construction

4. Nylon slings: For picking and setting the pole 5. Tamper: For use when backfilling around the pole after it is set into the hole 6. Drills and bits (step bits and/or hole saws): For use in field-drilling holes for framing

and/or climbing (note, having both an electric and battery-powered drill is useful; also, having a magnetic-base drill to use will be beneficial if steel greater that 3/16-inch thick is to be drilled)

7. Pole steps*: Sufficient supply of utility’s standard climbing step for fitting the entire pole 8. Safety equipment: All students must be properly equipped before being allowed to do

any hand-on work. Such equipment includes: Hard hat, work boots, gloves, safety glasses, climbing harness, lanyard and tool belt (when climbing), etc. All such equipment must comply with the utility’s required work practices.

9. Other items: Plumb bob, string, electrical cord (for drill), drilling lubricant, water (if excavated soil is dry), drinking water, megaphone (if class size is large), and digital camera (for group picture).

* The American Iron and Steel Institute may be able to donate a steel pole and climbing steps to qualifying schools. Please contact AISI for more information:

E-mail: [email protected] Web: lineman.steel.org


mailto:[email protected]

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