By Duane Oliver
In 1997, the Arizona Public Service Company (APS) implemented a pilot program to test the overall performance of steel distribution poles in the area it serves. The steel poles came through with high marks for ease of installation, durability, safety and cost.
A Need For Change
Arizona Public Service's search for alternative materials got serious after an extremely damaging summer season, when strong winds wreaked havoc on the company's distribution-pole system. The necessary repairs were costly, both in expense and lost labor time. APS continues to seek the competitive edge. Steel poles provide advantages that help achieve this goal.
"We began to look for ways to increase the longevity and reliability of our distribution structures," Duane Oliver, construction supervisor for the Northwest Division, remembers. "More than that, we had to stop the damage caused to the system when we lost one structure. Often, one pole would go down, and it would cause a domino effect with other poles. We saw this in all seasons, with high winds in the summer, or with snow and ice in the winter. This was not acceptable."
An Experiment That Worked
A team was assembled to look for ways to build a better system. It included members of the APS's standards department, engineering, environmental, procurement, construction crews and management -- it was an inclusive company effort. The group met with different material representatives -- concrete, wood, fiberglass, and steel. They reviewed alternatives, analyzed costs and safety factors, and came to the conclusion that steel stood out as a high-quality and cost-effective alternative to wood.
With this information, the Northwest Division asked APS if it could implement the pilot program with steel distribution poles to put them to a real-life test.
Shaun Whitey, section leader for the Arizona Public Service Transmission and Distribution Engineering and Standards Department, comments that Oliver's division was charged with 'ironing out the bugs' so the steel distribution-pole system could be used on a division-wide scale.
"We gave the go-ahead for the project with these conditions: As the division's construction supervisor, Duane had to make the commitment to communicate with the troops, give steel an unbiased trial, and provide candid feedback to us on his findings," Whitey says.
Adapting To Change
One of the most critical tests was how well linemen would adjust to using a different material. According to Oliver, the transition in Prescott went smoothly. "The crews were open-minded, and understood that things change."
"The crews were involved in all steps of the process," Oliver explains. "They helped make decisions and set the standards. We owe much of the success of the pilot program, and the quality system we now have in place, to them. They got behind the trial process and made the transition happen."
He adds that the pilot program was a success in large part because the crews saw the advantages of using steel. "We all dove in head first, and resolved issues as they arose. We've never regretted our decision to give steel a real try."
As positive an experience as the Northwest Division had, companies should not underestimate the culture-change impact this transition will have on their employees. Following the pilot program, APS put together a special Distribution Steel Pole Committee that resolved many significant issues relating to materials, safety, transportation, tools, and design.
The committee, which was created to bring closure to issues identified in the pilot program, consisted of representatives from the union, safety, engineering and standards and construction. The committee traveled to every construction dock in the company to communicate the changes and improvements made to the steel-pole construction process. In addition, crews were offered hands-on demonstrations of the new tools and materials recommended by the committee. It was a good opportunity to verify that the end product would be successful throughout APS.
Steel Offered Substantial Benefits
In Oliver's opinion, steel distribution poles offer several advantages to APS, and in general.
When a steel pole is damaged, it may not require immediate repair. This can eliminate off-hours work, which results in costly overtime and can become a safety issue to tired crews.
Steel poles can be pre-drilled to a utility's specifications by the manufacturer. This allows pre-planning for other services, such as cable television and telephone, to share the pole and for the addition of electrical equipment.
Steel poles are at least 30 percent lighter than wood poles, which makes them easier to transport and install. "Using steel allows us to move more poles at a time with less stress on the equipment," Oliver says.
Dispelling Steel Pole Misconceptions
Oliver comments that misconceptions about steel poles may deter some utility companies from giving them serious consideration as an alternative to wood.
One of the most common misconceptions is that steel poles cost more than wood. Oliver refutes this myth. "The longevity of steel poles is greater than wood, which makes them cheaper in the long run. People will say that wood poles last as long, but typically they don't," he says. "The exception is a wood pole made of cedar. But cedar is almost impossible to come by now, and when it is available, it can cost more than steel. If you evaluate the life-cycle costs of both wood and steel, APS believes steel is the best choice."
Another misconception is that linemen will only work with wood. Oliver says, "One of the concerns in the industry is how field crews will feel about using steel, when they're accustomed to working with wood."
"Some apprehension is common among linemen," he adds. "As long as crews strictly follow all the safety rules they should use when working with wood poles, there shouldn't be any problems with steel."
The safety of steel distribution poles is another misconception. Oliver believes that the safety concerns associated with steel are blown out of proportion. "There shouldn't be a great difference in the way you handle wood and steel. The NESC does not differentiate between the types of materials used for poles. They should all be treated as conductive."
He continues, "You simply take the same safety precautions for wood and steel, and follow them to the letter. Every company needs to take a good look at their safe-working rules and ensure that there are no gaps. All safety issues must be addressed."
Despite the initial nervousness about working with a 'new' material, Oliver says that the linemen adapted well. "Not only did the crews follow the rules, but they -- together with the standards department and steel-pole task team -- established additional guidelines and safety standards for the steel installation. Also, the linemen were allowed to adapt to steel on their own schedules -- no one was forced into a set pace."
Oliver believes that the way steel was introduced to the APS crews paid off. "Now that the guys are experienced with steel, they prefer to use it," Oliver says. "Even when told to use wood, they've been caught sneaking out a steel pole."
Room to Grow
With these and other positive field results, steel poles are becoming the standard for APS on a company-wide scale.
In the three years since the pilot program was initiated, steel has become the distribution pole of choice for the Northwest Division of APS. And, totally sold on the ease of installation and its durable nature, steel is the pole of choice throughout the entire company.
During the past year, the Northwest Division of APS installed some 700 steel distribution poles. And, from June 1999 to June 2000, the company installed almost 5,500 new steel poles throughout its distribution system. Only 1,462 new wood poles were installed in the same period of time.
APS is proud of the fact that this diverse group took on a problem that needed real solutions, and by working in tandem, found successes. Oliver concludes, "The success of the pilot program at APS is due to the support and hard work of many people -- from executive management to the front-line crews."
Duane Oliver, is Construction Supervisor for Arizona Public Service Company.