Engineering Test Report MacLean Power Systems Cumulative Crossarm Test Report For: PX, PW, PW-SPDE, PZ, PY Profiles Version: A Date: 1/27/14 Page 1 of 15
ABSTRACT A cumulative test report was assembled from multiple testing dates to represent the MPS crossarm line. Loading capabilities were established for assembled and unassembled units. Included are bolted capacities, attachment loading capabilities of iron bases, UV degradation, and hydrophobicity of the surface. Mike Valenza Product Manager Tyler Krohn Design Engineer Page 2 of 15
TEST REPORT NO.: TR 13-007 DATE TESTED: 1-3) 07/13 4) 03/13 5a) 02/11 5b) 12/12 ITEMS TESTED: PX- Standard Tangent Applications PW- Heavy Duty Tangent Applications PW-SPDE- High Strength Small Profile Deadend Applications PZ- Light Duty Deadend Applications PY- Heavy Duty Deadend Applications PERFORMED TESTS: 1) Bending Test of Assembled Units a. PY - Horizontal and Vertical Axis b. PZ - Horizontal and Vertical Axis c. PW-SPDE - Horizontal and Vertical Axis d. PW - Vertical Axis e. PX - Vertical Axis 2) Bending Test of Unassembled Profile a. PY - Horizontal Axis b. PZ - Horizontal Axis c. PW-SPDE - Vertical Axis d. PW - Vertical Axis e. PX - Vertical Axis 3) Bolted Connection Bearing Capacity Test a. PY - 3/4 Hardware b. PY - 5/8 Hardware c. PZ - 3/4 Hardware d. PZ - 5/8 Hardware e. PX - 5/8 Hardware 4) PZ/PY Iron Deadend Attachment Loading Capacity a. Top Eye Only b. Bottom Eye Only c. Dual Eyes 5) UV Aging and Hydrophobicity Testing a. Accelerated UV Aging of Crossarm Surface b. Hydrophobicity Analysis of Aged Samples Page 3 of 15
BENDING OF ASSEMBLED UNITS: Crossarm assemblies of three different lengths were tested to evaluate their loading capabilities and characteristics. Five samples each of three different lengths, 6ft, 8ft, and 10ft, were tested to represent a large portion of the product offering. All specimens were completely assembled and tested to actual orientation and hardware attachments to represent in field loading conditions. The deadend profiles (PY, PZ, PW-SPDE) were loaded with attachments mounted 6 from the end of the member and tested in both the horizontal and vertical directions. The tangent profiles (PW, PX) were loaded with attachments mounted 4 from the end of the member and tested only in the vertical direction. The deflection characteristics were measured at corresponding attachment locations. A PZ deadend assembly being tested in the horizontal direction and test rig can be viewed in Figure 1. Figure 1: Assembled Horizontal Hardware Setup Test results for the assemblies can be viewed in Tables 1-8. Note that the 6 PY sample in Table 1 is missing both standard deviation and rating. This is a result of a reduced number of data points that were available after testing was completed. Page 4 of 15
Table 1: PY Assembled Horizontal Results PY ASSEMBLED HORIZONTAL TESTING 6 32,043-12,500 0.08 8 29,348 27,848 12,500 0.22 10 22,515 21,474 11,000 0.42 Table 2: PY Assembled Vertical Results PY ASSEMBLED VERTICAL TESTING 6 13,250 12,882 6,400 0.40 8 10,821 10,217 4,600 0.54 10 10,039 9,689 3,600 0.97 Table 3: PZ Assembled Horizontal Results PZ ASSEMBLED HORIZONTAL TESTING 6 27,680 22,163 9,400 0.10 8 24,939 22,722 9,400 0.24 10 17,851 14,772 7,300 0.47 Table 4: PZ Assembled Vertical Results PZ ASSEMBLED VERTICAL TESTING 6 10,118 9,860 4,900 0.51 8 8,238 8,024 3,500 0.79 10 6,706 6,567 2,800 1.20 Page 5 of 15
Table 5: PW-SPDE Assembled Horizontal Results PW-SPDE ASSEMBLED HORIZONTAL TESTING 6 27,003 28,044 10,200 0.15 8 21,719 21,059 10,200 0.35 10 16,485 15,993 7,900 0.70 Table 6: PW-SPDE Assembled Vertical Results PW-SPDE ASSEMBLED VERTICAL TESTING 6 9,945 9,805 4,900 0.45 8 8,952 8,326 3,500 0.81 10 7,566 7,247 2,800 1.57 Table 7: PW Assembled Vertical Results PW ASSEMBLED VERTICAL TESTING 6 17,752 16,523 7,200 0.29 8 16,025 15,137 7,200 0.60 10 13,108 11,432 5,700 0.90 Table 8: PX Assembled Vertical Results PX ASSEMBLED VERTICAL TESTING 6 8,677 7,856 3,200 0.33 8 6,719 6,433 3,200 0.68 10 6,276 6,005 2,500 1.28 Page 6 of 15
BENDING OF UNASSEMBLED UNITS: Crossarm members of three different lengths were tested to evaluate their loading capabilities and characteristics. Five samples each of three different lengths, 6ft, 8ft, and 10ft, were tested to represent a large portion of the product offering. All specimens were the beam element of each product type with no hardware attached or corresponding holes drilled. Each member was loaded in the direction of intended use, PY, PZ, and PW-SPDE in the horizontal direction, and PW, PX in the vertical. The purpose of testing unassembled profiles is to capture the differing loading characteristics between assembled and unassembled units. Under varying assembly configurations and loading scenarios the fixture hardware assembly can increase or reduce the overall structure strength. This is mainly observed through single or double shear configuration of the attachment bolts, and the corresponding torque induced on the fixture assembly. The profiles were placed in/on their corresponding base without attachment hardware, and the actuator reversed to push at the attachment points. The load application area consisted of a 4 wide bearing surface that allowed for rotation due to specimen deflection. As consistent with the assembled test, the deadend profiles had the loading applied 6 from each end and the tangent profiles at 4. The deflection characteristics were measured at corresponding load bearing locations. This assembly can be viewed in Figure 2. Figure 2: Assembled Vertical Hardware Setup Test results for the members can be viewed in Tables 9-13. Page 7 of 15
Table 9: PY Beam Horizontal Results PY MEMBER HORIZONTAL TESTING 6 40,450 37,703 0.08 8 28,144 27,173 0.21 10 19,740 18,579 0.40 Table 10: PZ Beam Horizontal Results PZ MEMBER HORIZONTAL TESTING 6 27,610 24,018 0.09 8 22,392 20,977 0.23 10 15,861 14,315 0.46 Table 11: PW-SPDE Beam Horizontal Results PW-SPDE MEMBER HORIZONTAL TESTING 6 25,422 24,397 0.14 8 18,908 18,299 0.35 10 14,849 14,214 0.71 Table 12: PW Beam Vertical Results PW MEMBER VERTICAL TESTING 6 21,606 20,237 0.16 8 16,383 15,167 0.39 10 13,300 12,819 0.80 Table 13: PX Beam Vertical Results PX MEMBER VERTICAL TESTING 6 10,420 9,649 0.25 8 6,878 6,433 0.63 10 6,216 5,726 1.29 Page 8 of 15
BOLTED CONNECTION BEARING CAPACITY: The bolted connections crushing load of PX, PZ, and PY profiles were established for 5/8 and 3/4 hardware. A hole was drilled through the center line of an 8 sample and grade 8 pins were used to ensure crossarm failure. The samples were loaded until bearing failure was achieved. The testing apparatus can be observed in Figure 3. Figure 3: Connection Bearing Test Setup The resulting failure loads for each profile type and pin size combination can be viewed in Table 14. Page 9 of 15
Table 14: PX, Z, Y Bearing Capacity Results Ultimate Bolt Bearing Load Profile/ Bolt Dia PX-5/8" 5,972 5,854 PZ-5/8" 9,406 9,113 PY-5/8" 10,207 9,808 PZ-3/4" 9,591 9,326 PY-3/4" 10,663 10,394 The bolted bearing capacity is dependent on two things; the physical material property and wall thickness of the profile. Because of this, assuming a constant material property across all profile types, the bearing capacity can be approximated for the remaining profile types based on their wall thickness and derived test data. These ratings can be viewed below in Table 15. Table 15: Bearing Capacity s Ultimate Bolt Bearing Load Profile/ Bolt Dia PX-5/8" 5,800 PW-5/8" 9,800 SPDE-5/8" 9,800 SPDE-3/4" 10,300 PZ-5/8" 9,100 PZ-3/4" 9,300 PY-5/8" 9,800 PY-3/4" 10,300 Page 10 of 15
PZ/PY IRON DEADEND ATTACHEMENT LOADING CAPACITY: Iron deadend crossarm bases were tested to establish guy eye ratings. Base specimens assembled with a crossarm member to simulate in field loading scenarios. The load application angle of 30 degrees was selected to represent in field loading conditions. Three separate loading scenarios were tested, top guy hole, bottom guy hole, and both guys holes loaded simultaneously. The testing apparatus can be viewed for single and double loading scenario in Figures 4 and 5 respectively. The results for individual and combined eye attachment loading can be viewed in Table 16. Figure 4: Single Guy Hole Loading Fixture Page 11 of 15
Figure 5: Double Guy Hole Loading Fixture Table 16: Iron Base Attachment s Test Type Load at 30 Deg Top Eye Attachment 30,000 Bottom Eye Attachment 30,000 Dual Eye Attachments 40,000 Page 12 of 15
ACCELERATED UV AGING: UV and condensation testing was completed to establish environmental aging characteristics on the MPS standard resin system. Test samples were prepared from full production sections of fiberglass material. Material was exposed to fluorescent ultraviolet (UV) light and condensation per ASTM G154. Exposure conditions consist of alternating periods of UV exposure and moisture exposure at 60 C and 50 C respectively. Testing was completed through 12,500 hours with the typical pass/fail criteria only requiring 2500 hours of testing. Samples at time zero and 3,000 hours can be viewed in Figure 6. Figure 6: 0hr Time Sample on Left, 3,000hr Sample on Right Visual analysis at the universally accepted 2,500 hour mark showed no exposed fibers or surface blooming. This indicates that all UV blocking agents remain intact through this period of aging. The only visual deterioration observed was a fading of the original color. The observed fading is normal and consistent with this composite material s exposure to the elements. Samples remained in the chamber past the 2,500 hour mark and removed every 1,000 hours to analyze aging characteristics. The outermost layer of UV protection, polyester veil, started to deteriorate at the 7,000 hour mark. After which, the deterioration increased slightly to the 12,500 hour mark, where small signs of fiber blooming are starting to show. This blooming appears to be only visual, physical touch cannot feel, and the sample is still aesthetically and physically acceptable. The 12,500 hour sample can be viewed in Figure 7. Figure 7: 12,500hr Showing Minor Signs of UV Deterioration Page 13 of 15
HYDROPHOBICITY TESTING: Hydrophobicity was established throughout the aging life of the MPS standard resin system. Water droplet contact angle was used to establish the degree of hydrophobicity of the sample. Aged UV degradation samples per ASTM G154 were tested for their level of hydrophobicity. A total of 12 samples were tested, starting with zero UV exposure through 12,500 hours. Data points were taken every 1,000 hours through the first 10,000 hours, then again at 12,500 hours. The measuring method to determine the contact angle of a water droplet is shown below in Figure 8. Figure 8: Schematic of Sessile Water Drop Contact Angle Measurements Samples were cleaned and placed on a leveled platform and aligned. Distilled water was applied through a syringe forming a 1mm drop 5mm above the sample surface. The drop was then lowered to the sample, where it detached from the needle, and the resulting contact angle was measured. This was repeated (6) times per sample at random locations on each sample. The resulting droplet and angle measurement is visible in Figure 9. Figure 9: Drop Measurement Image, 9000 hr Sample at t=0 Min. The resulting data for each sample was averaged and complied to derive a contact angle vs. UV exposure curve. The trend shows that contact angle increases with life through the first 3000 hours then plataues around 102 degrees. This graph can be viewed in Figure 10. Page 14 of 15
Contact Angle (deg) MACLEAN POWER SYSTEMS Sessile Drop Contact Angle at t=0 min 110 100 90 80 70 60 50 0 2000 4000 6000 8000 10000 12000 14000 Hours of Exposure Figure 10: Contact Angle vs. Hours of UV Exposure In reviewing the measurement method to determine the contact angle, it is evident that as the level of hydrophobicity increases with contact angle. From the contact angle vs. hours of exposure graph in Figure 10 it can be concluded that the hydrophobicity of MPS standard resin increases with time through the first 3000 hours of exposure. It then remains at the peak level with little fluctuation over then next 9,500 hours of testing. Page 15 of 15