As demand for electricity grew, grid capacity was increased by adding higher-performing conductors without altering the pylons’ design. Under current trends, however, this capacity will need to double every ten years, and current pylons are not strong enough. With additional challenges posed by climate change, there is an urgent need to build taller and stronger pylons.

The most common profiles used to build steel lattice towers are angle sections. In its portfolio, ArcelorMittal has developed heavy steel angles – such as L300 x 300 – produced in S460 steel quality. S460 offers significantly higher mechanical strength compared to S355. ArcelorMittal R&D has performed detailed analysis, which shows how the combination of the higher steel grade and stronger profiles could realistically meet the demands of electrical pylons in a rapidly evolving energy grid.

This research has validated the applicability of existing design rules and regulatory frameworks specifically for L300 × 300 angle sections in steel grade S460. Additionally, electricity pylons built in the proposed configuration allow for approximately 20% weight reduction, while offering higher structural resistance compared to existing pylons in S355.

Combining L300 × 300 angle sections with steel grade S460 for the main structural members of steel lattice towers results in increased capacity required by higher-performing conductors. This new design approach is fully compliant with current regulations.

Restructuring the energy grid in this way could reduce weight for towers of similar typologies made in S355 and smaller angles. It could also significantly reduce fabrication effort, time and costs.