After years of challenging traditional tower designs, BYSTRUP conceived the idea of making a high voltage Composite Pylon. Using this material, the pylon could be made more efficient, durable, and compact. Benefits that would ease the challenges in the global grid expansion for any operator or utility.
In 2013, the Composite Pylon idea received public funding from the Danish Innovation Fund to start the basic research to validate the concept, in partnership with TUCO Marine Group, the Danish Technical University, and Aalborg University.
The technology was subject to detailed structural analysis and validation by international experts and world leading universities in composite material manufacturing to ensure a feasible design. Computer simulations were run on geometry from Computer Aided Design (CAD) models showing good structural and dynamic properties. Results from computer simulations were validated through lab testing of the composite material.
Several lab-tests were executed validating the performance of composite as a feasible structural, dynamic and electrical alternative to steel. Test samples of different composite layouts were mechanical tested showing superior structural and dynamic performance according to the normal overhead transmission line load specifications (2x400kV). The full scale (13m) composite arm was tested for both electrical and mechanical behaviour at the same time (combined loading event).
Based on these initial tests, the next step was to realize the entire high voltage pylon in full-scale, test and validate the concept.
To achieve this, BYSTRUP invited Reinhausen Power Composites, Nexans, Dervaux, and Valmont SM to participate in the project. Via the Fast Track to Innovation program offered by the European Union, funding was secured in 2019.