cnc machining testing of fiber composite reinforcement

Perry Precision Products Inc.

Product Testing

CNC Machining

Testing of Fiber Composite

Reinforcement Utility Products

UNIT ASSEMBLY FIELD TESTING

Submitted to:

Pole Life Systems, Inc.

Bob Butler

January 17, 2018

By: Lonnie Perry, Testing Engineer

Perry Precision Products, Inc.

a Delaware Company

(727) 232-0868

POLE LIFE SYSTEMS UNIT FIELD ASSEMBLY TESTING TO ANSI O5.1-2015

Product Category: Electrical Utility Industry

Submitted to: Pole Life Systems, Inc.

Testing Company: Perry Precision Products, Inc. (727) 232-0868

Measuring Equipment: Mark-10 MR01-5000 Force Sensor

Mark-10 Model M3i Digital Force / Torque Indicator

Mark-10 Model Plug & Test Software

Start date: 11/1/2017

End date: 12/8/2017

Product Material Data:

Fiber reinforcement type: e-glass Resin matrix type: isothalic polyester resin

Compacting force on reinforcement during cure: Resin bath system using Pultrusion process with a minimum of 50% glass reinforcement by volume where at least 90%

of the reinforcement is in the form of rovings and the surfaces of the parts are reinforced with continuous filament UV mat.

1.10 SCOPE – FIELD ASSEMBLY TESTING PER ANSI O5.1-2015

1.11 These test methods cover determination of the break strength of Pultruded

Composite Product Field Units or Accessory fails. Knowledge of these properties are used in providing for reliable and economical design with parts of different sizes, patterns and hardware to accommodate various electrical utility pole configurations.

1.12 Accessories description consist of the following brackets and connectors: i. 20” Standoff Bracket – Fiberglass Arm

ii. 25KV Post Insulator - Porcelain 8” Insulator iii. 15KV Post Insulator - Porcelain 6” Insulator iv. 25KV Pole Top Post – Porcelain Insulator v. 15KV Pole Top Pin – Brown Porcelain Style Insulator

1.13 Two test methods are used: The Cantilever and Compression Method. 1.14 The procedures specified in these test methods apply to pultruded composite part

assembly Units of post machined parts. 1.15 The values stated in foot-pound units are to be regarded as the standard. 1.16 Chart time values are given in 10 sec. intervals during the momentum of break/fail or

a pre-determined value deemed sufficient for the application.

A. Pultruded glass fiber composite support products attached to assembly units for utility pole application are tested according to ANSI O5.1-2015. Machined from the pultruded composite parts Force Testing as described.

NOTES:

i. Not shown, are the various clamping devices, such as C-Clamps, Bolts, and Chains.

ii. Drawings in Views are mainly used for dimensioning and don’t always reflect true parts.

iii. Illustrated below are a representation of the major test equipment and fixturing used:

Cantilever and Compression Methods – Applied

MACHINED PRODUCTS LIST–

Unit IS20

Front Support 20”

Unit VR30

Vertical 30” Reinforcement

Unit VR48


Unit VR72


ACCESSORY MAIN PARTS GALLERY –

25KV Pole Top Post 15KV Pole Top Pin 25KV Post Insulator 8”

20” Standoff Bracket – Fiberglass Arm

15KV Post Insulator 6” Channel Plate Flat 3X5” Channel Plate Raised 3X5”

-ANSI VERTICAL LOAD RATINGS- PARTS FOR THIS TEST ARE ATTACHED TO A UTILITY POLE USING UTILITY COMPANY 5/8” THRU BOLTS AND ACCESSORIES. ALL

COMPOSITE TEST PARTS ARE ATTACHED TO THE POLE ASSUMING THE TOP 5”-6” OF THE POLE HAS TOTALLY DETERIORATED

AWAY (ASSUMING THE CONDITION OF THE POLE 20 YEARS IN THE FUTURE). SOLID WOOD EXIST 8” BELOW TOP THRU BOLT.

TOP BOLT SHOULD REMAIN IN WOOD SHELL

2.10 FIELD ASSEMBLY TEST FOR VR30/IS20 6” POST VERTICAL (IN VERTICAL POST POSITION) VERTICAL

This testing was conducted utilizing locked down fixtures as shown in Fig. 2.10.1 and force was applied by a 20 ton Hydraulic Ram with a Mark-10 MR01-5000 Force Sensor Load Cell mounted to fixture load head, with Computer Data output capture software as charted.

Unit Assembly – 6” Post Vertical – Vertical Load

Accessory used 25KV Post Insulator

Figure 2.10.1 – Actual load test image (6” from pole) Figure 2.10.2 – accessory

Test Summary:

VR30/IS20 parts 6” post vertical – Vertical load applied to 1850 [lbf] , as in Fig. 2.10.1 distinct crack sounded and verified by observation. *Pic not available.

0

500

1000

1500

2000

13

16

19

11

21

15

11

81

21

12

41

27

13

01

33

13

61

39

14

21

45

14

81

51

15

41

57

16

01

VR30 6" Vertical Load

Load [lbF] Time [@10 sec. intervals]

VR30/IS20 Vertical Post Position 6”

Load [lbF] 1850

2.11 FIELD ASSEMBLY TEST FOR VR30/IS20 8” POST (IN VERTICAL POST POSITION) VERTICAL


Unit Assembly – 8” Post Vertical – Vertical Load

Accessory used 25KV Post Insulator 8”

Figure 2.11.1 – Actual load test image Figure 2.11.2 – accessory

Test Summary:

VR30/IS20 parts - 8” post vertical – Vertical – Vertical load applied to 1310 [lbf] , as in Fig. 2.11.1 distinct

crack sounded and verified by observation. *Pic not available.

0

500

1000

1500

1

23

45

67

89

11

1

13

3

15

5

17

7

19

9

22

1

24

3

26

5

28

7

30

9

33

1

35

3

37

5

39

7

41

9

44

1

46

3

VR30/IS20 Vertical Load


VR30/IS20 Vertical Post Position 8"

Load [lbF] 1310

2.12 FIELD ASSEMBLY TEST FOR VR48/IS20 6” POST HEAVY (IN VERTICAL POST POSITION) VERTICAL


Unit Assembly – 6” Post Vertical Heavy – Vertical Load



Test Summary:

VR48/IS20 parts - 6” post vertical heavy - cracked at 2100 [lbf] Vertical load applied, as in Fig. 2.12.1 until distinct cracks sounded and verified by observation. *Pic not available.

0

500

1000

1500

2000

2500

1

20

39

58

77

96

11

5

13

4

15

3

17

2

19

1

21

0

22

9

24

8

26

7

28

6

30

5

32

4

34

3

36

2

38

1

40

0

41

9




Load [lbF] 2100

2.13 FIELD ASSEMBLY TEST FOR VR48/IS20 8” POST HEAVY (IN VERTICAL POST POSITION) VERTICAL


Unit Assembly – 8” Post Vertical Heavy – Vertical Load


Figure 2.13.1 – Actual load test image Figure 2.13.2 – accessory Figure 2.13.3 – Cracks noted as shown

Test Summary:

VR48/IS20 parts - 8” post vertical heavy - cracked at 2000 [lbf] Vertical load applied, as in Fig. 2.13.1 until distinct cracks sounded and verified by observation. Cracks noted in Fig. 2.13.3.

0

500

1000

1500

2000

2500

1

21

41

61

81

10

1

12

1

14

1

16

1

18

1

20

1

22

1

24

1

26

1

28

1

30

1

32

1

34

1

36

1

38

1

40

1

42

1


Load [lbF] Time [@10sec. intervals]


Load [lbF] 2000

2.14 FIELD ASSEMBLY TEST FOR VR30/IS20 20” STANDOFF (IN DUAL BOLT STANDOFF POST POSITION) VERTICAL


Unit Assembly – 20” Standoff – Vertical Load

Figure 2.14.1 – Isometric demonstration Figure 2.14.2 - Transverse View

Accessory used 20” Standoff Bracket – Fiberglass Arm


Test Summary:

VR30/IS20 parts 20” standoff - cracked at 1200 [lbf] Vertical load applied, as in Fig. 2.14.3 until distinct cracks sounded and verified by observation. *Pic not available.

0

500

1000

1500

1 9

17

25

33

41

49

57

65

73

81

89

97

10

5

11

3

12

1

12

9

13

7

14

5

15

3

16

1


Load [lbF] Time [@10sec. Intervalls]

30” Dual Bolt Standoff Post Position 18"

Load [lbF] 1200

2.15 FIELD ASSEMBLY TEST FOR VR48/IS20 20” STANDOFF HEAVY (IN DUAL BOLT STANDOFF POST POSITION)

VERTICAL


Unit Assembly – 20” Standoff Heavy – Vertical Load

Figure 2.15.1 – Isometric demonstration Figure 2.15.2 - Longitudinal View



Test Summary:

VR48/IS20 parts - 20” standoff heavy - cracked at 1600 [lbf] Vertical load applied, as in Fig. 2.15.3 until distinct cracks sounded and verified by observation. *Pic not available.

0

1000

2000

1

16

31

46

61

76

91

10

6

12

1

13

6

15

1

16

6

18

1

19

6

21

1

22

6

24

1

25

6

27

1

28

6

30

1



48” Dual Bolt Standoff Post Position 18"

Load [lbF] 1600

2.16 FIELD ASSEMBLY TEST FOR VR30/IS20 PIN TYPE (IN POLE TOP POSITION W/IS20) VERTICAL


Unit Assembly – Pin Type Pole Top – Vertical Load

Accessory used - 15KV Pole Top Pin


Test Summary:

VR30/IS20 parts – pin type pole top 2000 [lbf] Vertical load applied, as in Fig. 2.16.1 test suspended when load reached goal of 2000 [lbf]. No cracks or damage observed in composite material parts.

0

500

1000

1500

2000

2500

1

15

29

43

57

71

85

99

11

3

12

7

14

1

15

5

16

9

18

3

19

7

21

1

22

5

23

9

25

3

26

7

28

1

29

5

30

9

32

3

33

7

35

1

36

5

37

9

VR30/IS20 Pin Type Vertical Load


VR30/IS20 Pin Type Pole Top 6”

Load [lbF] 2000

2.17 FIELD ASSEMBLY TEST FOR (2) VR30 PARTS (POST TYPE IN POLE TOP POSITION) VERTICAL


Unit Assembly – Pole Top Post – Vertical Load

Accessory used 25KV Pole Top Position

Figure 2.17.1– Actual load test image Figure 2.17.2 – accessory Figure 2.17.3 – Post Type in Pole Top

Test Summary:

(2) VR30 parts – Pole top post - 2500 [lbf] Vertical load applied, as in Fig. 2.17.1 test suspended when load reached goal of 2500 [lbf]. No cracks or damage observed in composite material parts.

0

500

1000

1500

2000

2500

3000

1

20

39

58

77

96

11

5

13

4

15

3

17

2

19

1

21

0

22

9

24

8

26

7

28

6

30

5

32

4

34

3

36

2

38

1

40

0

41

9

43

8

45

7

47

6

49

5

51

4

53

3

(2) VR30 Pole Top Post Vertical


(2) VR30 Post Type - Pole Top 8"

Load [lbF] 2500

-ANSI LONGITUDINAL LOAD RATING- PARTS FOR THIS TEST ARE ATTACHED TO A UTILITY POLE USING UTILITY COMPANY 5/8” THRU BOLTS AND ACCESSORIES. ALL

COMPOSITE TEST PARTS ARE ATTACHED TO THE POLE ASSUMING THE TOP 5”-6” OF THE POLE HAS TOTALLY DETERIORATED

AWAY (ASSUMING THE CONDITION OF THE POLE 20 YEARS IN THE FUTURE). SOLID WOOD EXIST 8” BELOW TOP THRU BOLTS.

TOP BOLT SHOULD REMAIN IN WOOD SHELL.

3.10 FIELD ASSEMBLY TEST FOR VR30/IS20 6” POST (IN VERTICAL POST POSITION) LONGITUDINAL


Unit Assembly – 6” Post Type – Longitudinal Load

Figure 3.10.1 – Longitudinal Post Load 6” Figure 3.10.2 - Actual load test image

Test Summary:

VR30/IS20 parts – 6” vertical post position - cracked at 1250 [lbf] Longitudinal load applied, as in Fig. 3.10.2 until distinct cracks sounded and verified by observation. *Pic not available.

0

500

1000

1500

1

15

29

43

57

71

85

99

11

3

12

7

14

1

15

5

16

9

18

3

19

7

21

1

22

5

23

9

25

3

26

7

28

1

29

5

VR30/IS20 Vertical Post



Load [lbF] 1250

3.11 FIELD ASSEMBLY TEST FOR VR30/IS20 8” POST (IN VERTICAL POST POSITION) LONGITUDINAL


Unit Assembly – 8” Post Type – Longitudinal Load

Figure 3.11.1 – Actual load test image Figure 3.11.2 - Actual load test image

Test Summary:

VR30/IS20 parts – 8” Vertical post position - cracked at 1200 [lbf] Longitudinal load applied, as in Fig. 3.11.1 and Fig. 3.11.2 until distinct cracks sounded and verified by observation. *Pic not available.

0

500

1000

1500

1

11

21

31

41

51

61

71

81

91

10

1

11

1

12

1

13

1

14

1

15

1

16

1

17

1

18

1

19

1

20

1

21

1

22

1

23

1

24

1

25

1

26

1

27

1VR30/IS20 Vertical Post

Load [lbF] Time [10@sec. intervals]


Load [lbF] 1200

3.12 FIELD ASSEMBLY TEST FOR VR30/IS20 20” STANDOFF BRACKET (IN DUAL BOLT STANDOFF POST POSITION)

LONGITUDINAL LOAD


Unit Assembly – 20” Standoff – Longitudinal Load

Figure 3.12.1– Isometric View 20” Standoff Figure 3.12.2 - Longitudinal View 20” Standoff



Test Summary:

VR30/IS20 parts – 20” standoff - cracked at 1000 [lbf] Longitudinal load applied, as in Fig. 3.12.3 until distinct cracks sounded and verified by observation. *Pic not available.

0

500

1000

1500

11

22

33

44

55

66

77

88

91

00

11

11

22

13

31

44

15

51

66

17

71

88

19

92

10

22

12

32

24

32

54

26

52

76

28

72

98

30

93

20

VR30/IS20 20" Dual Bolt Standoff


VR30/IS20 Dual Bolt Standoff 18"

Load [lbF] 1000

3.13 FIELD ASSEMBLY TEST FOR VR30/IS20 6” PIN TYPE (IN POLE TOP POSITION) LONGITUDINAL


Unit Assembly – Pole Top Pin – Longitudinal Load

Accessory used - 15KV Pole Top Pin

Figure 3.13.1 – Isometric demonstration Figure 3.13.2 – accessory

Figure 3.13.3 – Actual load test image Figure 3.13.4 - unit image

Test Summary:

VR30/IS20 parts – Pin type unit assembly - cracked at 1000 [lbf] Longitudinal load applied, as in Fig. 3.13.3 until distinct cracks sounded and verified by observation. *Pic not available.

0

500

1000

1500

1

13

25

37

49

61

73

85

97

10

9

12

1

13

3

14

5

15

7

16

9

18

1

19

3

20

5

21

7

22

9

24

1

25

3

26

5

VR30/IS20 Pin Type Longitudinal


VR30/IS20 Pin Type Pole Top 6”

Load [lbF] 1000

3.14 FIELD ASSEMBLY TEST FOR (2) VR30 PARTS (POST TYPE IN POLE TOP POSITION) LONGITUDINAL


Unit Assembly – Post Top Post – Longitudinal Load

Figure 3.14.1 – Isometric demonstration Figure 3.14.2 – Image of part - cracked

Figure 3.14.3 – Actual load test image

Test Summary:

(2) VR30 parts – Pole top position - cracked at 1200 [lbf] Longitudinal load applied, as in Fig. 3.14.3 until distinct cracks sounded and verified by observation. In Fig 3.14.2.

0

500

1000

1500

1

15

29

43

57

71

85

99

11

3

12

7

14

1

15

5

16

9

18

3

19

7

21

1

22

5

23

9

25

3

26

7

28

1

29

5

30

9

(2) VR30 Post Type


(2) VR30 Post Type Pole Position 8"

Load [lbF] 1200

4.10 SUMMARY / CONCLUSION – UNIT FIELD ASSEMBLY TESTING TO ANSI O5.1-2015

a. – The following charts in Fig 4.10 & 4.11 will show the overall summary of unit ratings.

UNIT FIELD ASSEMBLY TESTING PERFORMANCE INFORMATION

Part

Number

ANSI Vertical Load Rating

Unit Specifications

Length from pole = 6" 8" 10" 12" 14" 16" 18"

VR 30 1850 1310 1200 In Vertical Post Position used with IS20



VR 30 1500 1400 1300 1200 In Dual Bolt Standoff Post Position used with IS20



VR 30 Insulator Height = 2000 Pin Type in Pole Top Position used with IS20

VR 30 Insulator Height = 2500 Post Type in Pole Top Position used with (2) VR30

-Figure 4.10-

Part

Number

ANSI Longitudinal Load Rating

Unit Specifications

Length from pole = 6" 8" 10" 12" 14" 16" 18"







VR 30 Insulator Height = 1000 Pin Type in Pole Top Position used with IS20

VR 30 Insulator Height = 1200 Post Type in Pole Top Position used with (2) VR30

-Figure 4.11-

- INFORMATIVE

• Basic Cantilever and Compression method tests were performed to demonstrate unit loads, bend/break strengths for Vertical, and Longitudinal directions.

• The test hardware, such as clamps, brackets, bolts, and hold down fixtures were carefully placed as to Not impede or alter the true strength of the parts.

• These unit loads are thought to be above normal and adverse loads that may be applied in the field.

cnc machining testing of fiber composite reinforcement

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