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PH
Level 3

SAI Global
40 Blackall Street
Barton ACT 2600

ISBN 0 7337 7202 1

WEB www.ena.asn.au
FAX +61 2 6272 1566
+61 2 6272 1555

WEB www.sai-global.com
Energy Networks Association

SPECIFICATION
ENA DOC 012—2006

CROSS–ARM SUPPLY AND PERFORMANCE

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=
SPECIFICATION
CROSS-ARM SUPPLY AND PERFORMANCE
ENA DOC 012—2006
 DISCLAIMER
This document refers to various standards, guidelines, calculations, legal
requirements, technical details and other information.
Over time, changes in Australian Standards, industry standards and legislative
requirements, as well as technological advances and other factors relevant to the
information contained in this document, may affect the accuracy of the information
contained in this document. Accordingly, caution should be exercised in relation to
the use of the information in this document.
The Energy Networks Association (ENA) accepts no responsibility for the accuracy
of any information contained in this document or the consequences of any person
relying on such information.
Correspondence should be addressed to the CEO, Energy Networks Association,
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Level 3, 40 Blackall Street, Barton, ACT 2600.

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First published as ENA DOC 012—2006.

COPYRIGHT

© Energy Networks Association 2005

All rights are reserved. No part of this work may be reproduced or copied in any form or by any means, electronic
or mechanical, including photocopying, without the written permission of the Association.

Published by Standards Australia, GPO Box 476, Sydney, NSW 2001 for the Energy Networks Association, Level
3, 40 Blackall Street, Barton, ACT 2600.

ISBN: 0 7337 7202 1

 3 ENA DOC 012—2006

CONTENTS

Page
1 SCOPE........................................................................................................................ 5
2 REFERENCES ........................................................................................................... 5
3 DEFINITION.............................................................................................................. 6
4 PERFORMANCE CRITERIA .................................................................................... 6
5 MECHANICAL AND ELECTRICAL TYPE TESTS............................................... 11
6 OPTIONAL TEST .................................................................................................... 11
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 ENA DOC 012—2006 4

INTRODUCTION
This document was prepared by the Cross-arm Supply and Performance Working Group of
the ENA Power Poles and Cross-arms Committee. There were two compelling reasons to
develop this document—a decreasing availability of traditional highly durable hardwood
cross-arms and a need to evaluate cross-arms of a wide range of materials and constructions
that are offered to the electricity supply industry.
The aim of the document is to specify performance criteria that will allow for maximum
innovation in material and construction variants in cross-arms that will be incorporated into
existing and future networks in Australia and New Zealand.
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 5 ENA DOC 012—2006

Energy Networks Association

Cross-arm supply and performance specification

1 SCOPE
The scope of this document is limited to performance criteria that will allow the evaluation
of equivalent cross-arms to the traditional timber cross-arms of hardwood species of
Durability Classes 1 and 2 and Strength Groups 1 and 2. The cross-arms will fall into two
distinct groups—
(a) those that will be direct replacements for existing hardwood cross-arms and use the
same hardware; and
(b) those that will have integrated hardware that will allow them to be used as direct
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replacements for existing hardwood cross-arms.

2 REFERENCES
AS 1222.1—1992 Steel conductors and stays—Bare overhead, Part 1: Galvanized
(SC/GZ)
AS 1222.2—1992 Steel conductors and stays—Bare overhead, Part 2: Aluminium clad
(SC/AC)
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AS 1604.1—2005 Specification for preservative treatment, Part 1: Sawn and round

timber
AS 1720.1—1997 Timber structures, Part 1: Design methods
AS 1824.1—1995 Insulation co-ordination, Part 1: Definitions, principles and rules
AS 2650—2005 Common specifications for high-voltage switchgear and controlgear
standards
AS 3818.4—2003 Timber—Heavy structural products—Visually graded, Part 4:
Cross-arms for overhead lines
AS 4435.1—1996 Insulators—Composite for overhead power lines—Voltages greater
than 1000 V a.c., Part 1: Definitions, test methods and acceptance
criteria for string insulator units
AS/NZS 1170.2:2002 Structural design actions, Part 2: Wind actions
AS/NZS 2947.1:1999 Insulators—Porcelain and glass for overhead power lines—Voltages
greater than 1000 V a.c., Part 1: Test methods—Insulator units
AS/NZS 4676:2000 Structural design requirements for utility services poles
AS/NZS 4680:1999 Hot-dip galvanized (zinc) coatings on fabricated ferrous articles
ESAA C(b)1—2003 ESAA Guidelines for design and maintenance of overhead
distribution and transmission lines
IEC 60093:1980 Methods of test for volume resistivity and surface resistivity of
solid electrical insulating materials
IEC 60721-2-1:2002 Classification of environmental conditions, Part 2-1: Environmental
conditions appearing in nature—Temperature and humidity

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 ENA DOC 012—2006 6

3 DEFINITION
The following definition of cross-arm is a revision of that contained in AS 3818.4.
‘Cross-arms form the supporting crosspieces fixed to utility service poles to which
overhead plant is attached. Plant includes conductors, insulators, switchgears, transformers,
etc.’

4 PERFORMANCE CRITERIA
Compliance with the following performance criteria will be required:
• Design life
• Strength
• Electrical properties
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• Durability
• Maintenance
• Environmental parameters
• Compatibility and interchangeability
• Design changes
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• Weight
• Storage and handling
• Workability
• Cost of ownership
4.1 Design life
The definition of design life in AS 1720.1 has been selected. AS 1720.1 states:
‘Design life—the period over which a structure or structural element is required to perform
its function without repair.’
The design life for cross-arms is 40 years.
4.2 Strength
The cross-arm shall be capable of resisting dead, tensile, live and wind loads and designed
according to recognised structural design principles. Other loads acting on the cross-arm
shall be included where appropriate, e.g. snow or ice loads.
A description of some of the loads acting on the cross-arm are given below in Clauses 4.2.1
to 4.2.3 and shown in Figure 1.

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 7 ENA DOC 012—2006

= Crushing forces

Tension from the angle of

conductors or wind loads

Weight of conductors and

insulators, plus wind and snow loads

Weight of cross-arm
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FIGURE 1 ILLUSTRATION OF LOADS ON CROSS-ARMS

4.2.1 Dead loads

Dead loads include:
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• Weight of the cross-arm.

• Localised crushing loads at the connection points for the braces and at the king bolt.
• Weight of the conductors (transmission cables) which will vary for conductor type
and span (see AS 1222.1 and AS 1222.2).
• Weight of the insulators.
4.2.2 Tensile loads
• Loads due to tension in the suspended cables especially at the end of cable.
• Tension in the direction parallel to the cross-arm due to conductor angles.
• Torsion loads due to eccentric or unbalanced loading from conductors.
4.2.3 Live loads
Live loads include:
• Construction loads—100 kg.
• Pole top rescue loads—200 kg.
• Unbalanced loads due to broken conductors.
4.2.4 Wind loads
• For wind loads see AS/NZS 1170.2 and ESAA C(b) 1.
4.2.5 Long-term loading factors
Appropriate long-term loading factors need to be used to allow for the design life of the
cross-arms.
4.2.6 Concurrent factors
Concurrent factors to allow for the interaction of loads need to be considered. These are
available for wood cross-arms in ESAA C(b) 1, AS 1720.1 and AS/NZS 4676.

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 ENA DOC 012—2006 8

4.2.7 Serviceability
The deflection of the cross-arm under the dead loads shall be limited to a maximum of 5%
of bendable length.
4.3 Electrical properties
For cross-arms to be considered to be insulating, they must satisfy the following criteria for
Basic Insulation Level and electrical resistance.
4.3.1 Basic insulation level (BIL)
BIL is a measure of insulated components to withstand lightning surges.
A minimum BIL of 300 kV/m is required for cross-arms when tested in accordance with
AS 1824.1.
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4.3.2 Electrical resistance

Electrical resistance is a measure of the extent to which electrical current would flow along
a cross-arm, down the pole and into the ground during a fault. The minimum required
electrical resistance for cross-arms is 105 ohms/m, which is the reported electrical resistance
of unseasoned tallowwood cross-arms.
If cross-arms do not satisfy the above criteria for BIL and electrical resistance, they will be
classified as non-insulating and the product supplier must advise the purchaser of their
electrical properties.
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Cross-arms with integrated hardware should be tested to determine the electrical resistance
of the assembly. The test should be relevant to the intended application (LV or HV).
Relevant test methods are contained in IEC 60093.
4.4 Durability
The cross-arms must be sufficiently durable to perform their function in Australia and New
Zealand for the 40 year design life specified in Clause 4.1.
There are ranges of climatic zones in which the cross-arms may be used, ranging from arid
to tropical, temperate and cool continental. The climatic parameters of these zones are
specified in IEC 60721-2-1.
It is possible that data or previous experience may warrant restricting the use of some
cross-arms to less than the complete range of climatic zones, possibly subject to additional
performance data in excluded climatic zones being developed. Suppliers of cross-arms must
advise purchasers of the climatic zones in which data and/or experience support their use.
There are five durability parameters to be considered:
• Resistance to attack by natural agents—both physical and biological.
• Form and dimensional stability.
• Permanence of adhesives and mechanical fastening systems.
• Resistance to corrosion.
• Resistance to fire damage.
4.4.1 Resistance to attack by natural agents—both physical and biological
The cross-arms must be sufficiently resistant to attack by both natural physical and
biological agents to provide the 40 year design life specified in Clause 4.1. Physical agents
include ultraviolet light, rainfall, high humidity, high temperatures and freezing
temperatures. Refer to AS 2650, which outlines service conditions throughout Australia and
New Zealand.

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 9 ENA DOC 012—2006

For timber cross-arms or cross-arms with timber components, heartwood timber of

Durability Class 2 or better will be deemed to comply. Timber of lower durability must be
treated with preservatives in accordance with AS 1604.1.
For cross-arms fabricated from other materials, the product supplier must provide data to
demonstrate the ability of the cross-arms to perform for the required design life of 40 years.
4.4.2 Form and dimensional stability
Dimensional stability includes the tendency to shrink, twist or sag in service. Where test
data is developed to support the dimensional stability of a cross-arm, the cross-arm must be
tested under static loads and climatic conditions that simulate those that would be applied in
service.
4.4.3 Permanence of adhesives, coatings and mechanical fastening systems
All adhesives and mechanical fastening systems must be capable of performing adequately
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for the 40 year design life of the cross-arm. Where coatings form an integral part and affect
the mechanical and or electrical strength of the cross-arm, they must be capable of
performing adequately for a 40 year design life.
For cross-arms with timber components (e.g. veneers and laminates) adhesives complying
with appropriate Standards shall be used. Acceptable bond quality shall be demonstrated by
testing to Standards that are appropriate for the product.
For non-timber cross-arms, the product supplier will demonstrate long-term adhesive
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performance by testing to a Standard that is appropriate for the material(s) of construction.

The permanence of mechanical fastening systems must be demonstrated for material(s) used
in the manufacture of the cross-arm. To avoid premature failure due to corrosion or other
factors, it is critical that the impact of materials in contact with the fastening systems on
their long-term performance be determined.
4.4.4 Resistance to corrosion
Cross-arms and their component parts must be sufficiently resistant to atmospheric
corrosion to provide the 40 year design life specified in Clause 4.1.
Published data are available on the corrosion of steel in a wide range of environments.
Similar data would be needed to support the use of other materials.
The impact of dissimilar materials in the cross-arms on the corrosion rate of the material
being assessed needs to be considered.
4.4.5 Resistance to fire damage
Cross-arms may be subjected to types of fire attack—attack during bushfires and pole top
fires.
The cross-arms need to be at least as resistant to both types of fire attack as untreated
Durability Class 2 hardwood cross-arms.
4.4.6 Resistance to lightning and power arcs
Cross-arms shall be resistant to lightning and power arcs and shall not suffer any decrease
in the mechanical or electrical strength of the cross-arms. The applicable power arc test is
covered in Clause 5.4.
4.5 Maintenance
The cross-arm and any integrated fittings should preferably be maintenance free for the 40
year design life of the cross-arm.

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 ENA DOC 012—2006 10

4.6 Environmental parameters

There are two environmental parameters that need to be considered—visual acceptability
and end-of-life strategies.
4.6.1 Visual acceptability
The colour and appearance of the cross-arms must be acceptable to the community in which
they are used.
4.6.2 End-of-life strategies
End-of-life options will increasingly be a significant factor in the selection of cross-arms.
The cross-arm suppliers must provide an end-of-life strategy for their products. The ideal
will be reuse or recycling, with disposal being the least attractive option. The suppliers
must also identify their responsibilities and those of the purchaser in any Extended
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Producer Responsibility scheme that may be in operation.

4.7 Compatibility and interchangeability
Cross-arms must be compatible and interchangeable with current cross-arms and hardware.
4.8 Design changes
Within the scope of this document there can be no design changes arising from the use of
alternative cross-arms.
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4.9 Weight
The weight of cross-arms must not be greater than that of an equivalent Durability Class 2
hardwood species cross-arm. For a cross-arm of 100 × 100 mm section, the maximum
weight will be 12 kg/m.
If the cross-arm weight exceeds 12 kg/m, the product supplier will specify an appropriate
handling system.
4.10 Storage and handling
When the storage and handling requirements for a cross-arm differ from those of a
non-preservative-treated Durability Class 2 hardwood equivalent, the supplier shall specify
storage and handling requirements for their cross-arms.
4.11 Workability
Cross-arms need to be capable of being drilled and cut with hand and power tools that may
be used in the field for their assembly and installation.
Suppliers must advise purchasers of any precautions that must be taken when their products
are drilled and cut.
4.12 Cost of ownership
Estimates of the cost of ownership should be determined collaboratively between the
product supplier and purchaser, where required. Estimates must include all aspects from
purchase through storage, use and end-of-life strategies.

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 11 ENA DOC 012—2006

5 MECHANICAL AND ELECTRICAL TYPE TESTS

5.1 Average failing load test
The cross-arm shall be mounted in the standard manner (with a king bolt through the centre
of the arm) and subjected to a dead or tensile load applied at a distance of 100 mm from one
end. The bendable length shall be measured and load applied rapidly but smoothly from
zero to approximately 75% of the expected mechanical failing load, and then gradually
increased in a time between 30 sec and 90 sec until the cross-arm fails. Failure occurs when
there is a breakage of the cross-arm or when the cross-arm has permanently deflected more
than 10°.
5.2 Sudden load release test
The cross-arm shall be subjected to 5 sudden load releases when subjected to a dead or
tensile load of 30% of the average failing load. There shall be no breakage of the cross-arm
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after this test.

5.3 Dry lightning impulse withstand and 50% flashover voltage
For cross-arms regarded as insulating, the cross-arm shall be subjected to lightning impulse
voltage tests in accordance with AS/NZS 2947.1. The impulses shall be applied to 1 m of
cross-arm and both the impulse withstand and 50% flashover voltage shall be recorded.
5.4 Power arc test
The cross-arm shall be subjected to a power arc test in accordance with Appendix ZZ of
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AS 4435.1.
5.5 Resistance test
For cross-arms regarded as insulating, the resistance of 1 m of cross-arm shall be measured
using IEC 60093.

6 OPTIONAL TEST
6.1 Galvanising test
In the case of a steel cross-arm, the test shall be performed in accordance with
AS/NZS 4680.

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ENA DOC 012—2006

12

NOTES
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PH
Level 3

SAI Global
40 Blackall Street
Barton ACT 2600

ISBN 0 7337 7202 1

WEB www.ena.asn.au
FAX +61 2 6272 1566
+61 2 6272 1555

WEB www.sai-global.com
Energy Networks Association

SPECIFICATION
ENA DOC 012—2006

CROSS–ARM SUPPLY AND PERFORMANCE