40-3: 2008

CEB
SPECIFICATION

33KV FIBREGLASS REINFORCED

PLASTIC (FRP) CROSS ARMS

CEYLON ELECTRICITY BOARD

SRI LANKA

CONTENTS

PAGE

1.

Scope

2.

System Parameters

3.

Service Conditions

4.

Applicable Standard

5.

Basic Features

6.

Quality Assurance

7.

Additional Requirements

8.

Information to be Supplied with the Offer

9.

Sample Study

10.

Inspection and Testing

11

Annex

SPECIFICATION FOR FIBREGLASS REINFORCED PLASTIC

(FRP) CROSSARMS
1.0

SCOPE
This Specification Covers the design manufacture, testing supply and delivery of fiber
glass reinforced plastic (FRP) cross arms, for use in the MV overhead distribution lines in
the heavily polluted coastal areas, offered by Bidders who should also necessarily be the
manufacturers of the FRP material.

2.0

SYSTEM PARAMETERS
a)
b)
c)
d)
e)
f)

3.0

33kV
36kV
50Hz
03
Non effectively earthed
13.1 kA

SERVICE CONDITIONS
(a)
(b)
(c)
(e)
f)

4.0

Nominal Voltage
System highest voltage
System frequency
Number of phases
Method of earthing
System fault level

Annual average ambient temperature

30C
Maximum ambient temperature
40C
Maximum relative humidity
95%
Operational altitude
From MSL to 100mabove MSL
Environmental condition
i)
Humid and heavily polluted with deposits of sand, dust and salt from the
sea, industrial and agricultural pollution
ii)
Maximum temperature difference form day to night 250C.
iii)
Prolonged periods without rain (up to 10 months)
iv)
Long summer periods with lots of sunshine.

APPLICABLE STANDARDS
The fiber glass reinforced plastic (FRP) material and cross arm shall be tested in
accordance with the requirements of the latest published edition of the standard specified
below and amendments thereof
a)

ASTM D695 Standard test method for compressive properties of rigid plastics.

b)

ASTM - D635 Standard Test Method for rate of burning and / or extend and
time of burning of plastics in a horizontal position

c)

ASTM - D257 Standard test methods for DC resistance or conductance of

insulating materials.

d)

ASTM D149 Standard test method for dielectric breakdown voltage and
dielectric strength of solid electrical insulating materials at
commercial power frequencies

e)

ASTM G53

Operating light and water exposure apparatus (fluorescent UV (Fluorescent UV-condensation) for exposure of nonmetallic
materials.

All aspects, tests, etc. not covered by the above standard shall be executed
according to this standard to the fullest satisfaction of the purchaser.
5.0

BASIC FEATURES
5.1

Manufacture of Fiber Glass Reinforced Plastic Section

The fiber glass reinforced plastic (FRP) sections used to fabricate the cross arm shall be
made of brittle fracture-resistant, good quality high strength polyester based fiberglass
material suitable for coastal area application and to achieve maximum failing load and
conforming to standards specified.
The FRP sections shall conform to the following requirements.
a)
The glass content of the FRP material shall not be less than 55% by weight
b)
It shall be self extinguishing type when tested as per ASTM D635:
c)
Specific Gravity shall not be less than 1.8 when test as per ASTM
d)
Water Absorption shall not be more that 0.7% when test as per ASTM,
e)
Compressive Strength shall not be less than 1500 kg/sq cm when tested as per
ASTM D695
f)
Insulation Resistance shall not be less than 100M when tested as per
ASTM D257, BS 2050
g)
Dielectric Strength shall not be less than 6kv / mm when test
as per ASTM D149-92
h)
U.V. Resistance Test as per ASTM G53 for 1000 hours- with max limit of
reduction in Flexural strength should not be more than 3.5% in 1000 Hrs UV
radiation test.
i)
Wet power frequency withstand voltage on 1m length of cross arm shall not be .
less that 70KV.
i)
The mechanical (working) load shall not be less than that stated in Clause 5.3
below. Load Test. shall be carried out as stated below.
The 2 samples of each design from offered cross arm should be tested for Load
test , the mounting arrangement should be similar to the actual mounting of cross
arm on pole , with cross bracing and then Hydraulic Load to be applied on both
the ends without Insulator and the cross Arm should not Break or Crack at the
specified Load in Vertical mounting and Horizontal Mounting.
The FRP sections shall be manufactured by automatic pultrusion process and it shall be
of hollow Square / Rectangular cross section type, and Angle / Channel section type.
The FRP sections shall be mechanically sound, free from voids, foreign substances and
manufacturing flaws and the cut cross-section shall give a homogeneous appearance.
The FRP sections used to make the cross arm shall be suitable for out door application
and applied with UV resistance paint to prevent degradation due to UV radiation of
sunlight.
The FRP sections used to make the cross arms shall be of light colour, ash colour
preferred, and shall not deteriorate while in contact with steel fittings / fixtures and
concrete poles
5.2

Finish

The FRP cross arm surface shall be clean with smooth surface finish and be free from any
defect. The cut surface and drilled position shall be free from burs and sharp edges.

5.3

Mechanical Properties

The mechanical properties of FRP hollow shall not be less than value given below
in the table.
Description of
section
Vertical
Loading
Horizontal
loading
Minimum
Tensile
strength
5.4

110x55
mm

75x75
mm

100x100
mm

400 kg

400kg

500 kg

135 kg

135 kg

150 kg

4000 kg

4000 kg

4000kg

Fabrication

The Length of the 33KV cross arm shall be 2300mm. The Pin and Tension Cross
arm assembly shall be fabricated out of following sizes of FRP sections and as per
Drawing Nos. DS&S/2007/40-3A. & DS&S/2007/40-3B.respectively.
The pin Cross arm shall be made of Hollow type Rectangular sections of
75mmX75mm , or 110mmX 55mm as per Schedule of Prices
The tension cross arm shall be made of hollow type rectangular section 110 x 55
mm or square section of 100 x100mm as per Schedule of Prices
Position and size of holes on the cross arms, shall be precisely in accordance with
the drawing annexed.
To improve the mechanical strength of the cross arms and to prevent formation of
cracks due to excessive pressure applied at the place the bolts are tightened, solid
polymeric or Tubular FRP ferrules as packing material shall be provided at all hole
positions.
The Bracings made of angle or channel type FRP sections shall be provided as indicated
in the drawing No DS&S /2007/40-3A & 3B to mount the cross arm to the pole.
Necessary Bolts and nuts shall also be provided for mounting the cross arm to the pole
with the bracings. Necessary FRP Pack washers shall also be provided. .
For Tension cross arm necessary EYE Bolt and Eye Nut shall be provided as
indicated in the Drawing DS&S/2007/40-3A.
All Bolts and Nuts shall be hot dip galvanised and the galvanized coating
thickness shall not be less than 110 microns
5.5

Drawings

The FRP Tension and Pin Cross Arms Assembly shall be in strict accordance with
the Specifications and as per drawing Nos. DS&S /2007/40-3A and DS&S
/2007/40-3B
6.0

QUALITY ASSURANCE
The FRP manufacturer shall possess ISO 9001 quality assurance certificate for
manufacture of fiber glass reinforced plastics material and cross arms at the plant where
the manufacture is done. A copy of the ISO certificate, certified as a true copy of the
original, shall be furnished.

7.0

ADDITIONAL REQUIREMENTS
7.1

MARKING

Each cross arm shall be marked with the name or trade mark of the manufacturer, the
year of manufacture and the specified mechanical load. The marking shall be legible and
indelible.
7.2

Routine Tests

The following routine tests according to the standard specified, shall be carried out on
every batch and the routine test report shall be made available for the observation of the
CEB inspector at the time of inspection.
a)
b)
c)
d)
e)

Visual examination
Dimensional Check
Flammability test
Glass content Test
Load Test

7.3

Packing

Each cross arms shall be covered with stretch wrapping film on the winding machine and
10 to 20 cross arms shall be packed together in such manner to prevent any damage
during transport
Each shipping container shall have a packing list and in addition, shall be marked with
the following information.
a)
b)
c)
d)
e)
f)

Descriptive name
Quantity packed in container
Contract and lot number
Gross weight
Volume
Applicable standard

7.4

Guarantee

The manufacturer shall have a minimum of 15 years experience in the field of producing
pultruded FRP products and supplying for costal and offshore application..
The FRP manufacturer shall guarantee that all materials used in the manufacturing of the
FRP cross arm will be durable and able to withstand under the specified service and
Climatic conditions stipulated in Clause 3.0 above for at least 20 years.
8.0

INFORMATION TO BE SUPPLIED WITH THE OFFER

The bidder shall submit the following together with the offer.
a)

The catalogues indicating the model No. and technical literature

b)

General outline and cross-section drawing of the cross arm (All data and
descriptive material shall be in English and dimensions in metric units).

c)

Quality assurance certificate conforming to ISO 9001 for the pultrution of FRP
and cross arm fabrication

d)

Completed and filled-in schedule of guaranteed technical particulars

e)

Supply Record indicating the sales of FRP products/sections for last 15 years shall
be furnished indicating quantities and year of sale of FRP product to a minimum of
ten utilities

g)

The following Test Certificates conforming to the specified standard shall be

furnished as applicable
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)

Specific Gravity Test as per ASTM

Water Absorption Test as per ASTM,
Compressive Strength Test as per ASTM D695
Insulation Resistance Test as per ASTM D257, BS 2050
Dielectric Strength Test as per ASTM D149-92
U.V. Resistance Test as per ASTM G53 for 1000 hours
Wet power frequency withstand voltage on 1m length of cross arm.
Load Test. - shall be carried out as stated in Clause 5.1 i. above.

The Test Certificates furnished shall conform to the relevant standard, clearly identifying
the item, showing the manufacturer's identity, Type No. and basic technical parameters,
and it shall be from a recognized Independent Testing Authority acceptable to the
Purchaser.
Offers of Bidders who fail to furnish the above particulars and sample as requested
in clause 9.0 will be rejected.
9.0

SAMPLE STUDY
One sample of the FRP cross arm offered shall accompany the tender to facilitate analysis
and evaluation of the Bid. While analysing the sample, the Purchaser reserves the right to
check dimensions, inspect workmanship and perform essential tests as prescribed in the
relevant standards.

10.0

INSPECTION AND TESTING

10.1

Inspection

The selected Bidder shall make necessary arrangements for Engineers of the CEB to
inspect manufacturing processes and testing facilities available with the FRP manufacturer
and also to witness acceptance /sample tests on the FRP Cross arm offered.
10.2

Acceptance/Sample Tests

Following acceptance tests shall be witnessed by the CEB Inspector.

a)
Visual examination
b)
Dimensional Check
c)
Flammability test
d)
Glass content Test
e)
Load Test
11.0

ANNEX
A)

33KV Pin Cross arm Assembly Drawing No. No DS&S /2007/40-3A

B)

33KV Tension Cross arm Assembly Drawing No. No DS&S /2007/40-3B

ANNEX-A
SCHEDULE OF GUARANTEED TECHNICAL PARTICULARS
FOR FRP CROSS ARM
(To be filled by the Manufacturer)

Pin
Tension
Cross arm Cross arm
1)
2)
3)
4)
5)

6)
7)
8)
9)

10)
11)
12)
13)
14)
15)
16)
17)
18)
19)
20)
21)

Manufacturers name & address

Country of origin of FRP material
Model/Reference/Catalogue number
Whether the FRP section is manufactured by fully
automatic pultrusion method,
.
Yes/No. FRP material
a)
Applicable Standards
b)
Type (base)
c)
Glass content
d)
Specific Gravity
e)
Water Absorption
f)
Compressive Strength
g)
Insulation Resistance
h)
Dielectric Strength
i)
Method of U.V. resistance treatment
Yes/No. j)
Self extinguishing type
Yes/No. Dimensions of
a)
Rectangular /Square sections of cross arm
mmxmmb)
Angle/Channel Bracings
mmxmmNominal length
mm
Net weight
kg
Specified mechanical load
a)
Vertical
kg
b)
Horizontal
kg
c)
Tensile Strength
kg
Dry lightning impulse withstand voltage (peak) on 1m length kV Wet 1 min. power frequency withstand voltage on 1m
kV
Whether the Dimensional Drawings furnished
Yes/No Whether the GI Bolts & nuts and Eye Bolts & Eye nuts
are supplied with cross arms
Yes/No Galvanized Coating Thickness
Micron Whether FRP Inserts are provided at all hole positions Yes/No Type of Inserts provided
circular/ solid Whether FRP washers provided
Yes/No. Whether the quality assurance certificates furnished
for manufacture of FRP Material and Cross arm
Yes/No Whether the test certificates for FRP material issued by
a recognized Independent testing authority furnished
Yes/No Whether the supply record for last 15 years furnished
Yes/No. Method of packing
-

SEAL AND SIGNATURE OF THE FRP/CROSS ARM MANUFACTURER

DATE