A Comparison of Tubular Steel Pole Fabrication Technologies—Roll Formed vs. Press Broken Shapes

Fabricated tapered tubular steel poles represent approximately 80% of the non-wood, electric transmission "structures" sold in the United States. Most steel poles are press brake formed, either into a round shape through a "coining" process, or are multi-sided. As the requirement for ever larger, higher capacity, tubular steel poles grows, other technologies, primarily conventional steel plate roll forming technologies are being used. Steel roll forming technologies are widely used for large, storage tanks as well as wind turbine support structure fabrication, but not so commonly thought of for use in electrical transmission structure fabrication. This paper will compare and contrast the differences in the technologies and discuss design (both pole and connection designs), material efficiency, fabrication steps and processes, quality requirements, logistics/shipping, and field assembly/erection differences.