The Kawau Island Long Span project demonstrates how Fibre Reinforced Polymer (FRP) infrastructure is expanding the possibilities of overhead line design. Located on Kawau Island, New Zealand, the project features what is believed to be the world’s longest span achieved using an FRP utility pole, with an approximately 746 metre overhead line supported by Wagners CFT FRP utility poles and composite crossarms. Designed by Vector, the project showcases how innovative engineering, rigorous testing and lightweight composite infrastructure can work together to solve complex network challenges.
Watch the case study
Discover how Vector designed an approximately 746 metre overhead line span using Wagners CFT Fibre Reinforced Polymer (FRP) utility poles and composite crossarms. This project explores how innovative engineering, lightweight composite infrastructure and extensive technical validation combined to deliver what is believed to be the world’s longest span achieved using an FRP utility pole.
📺Watch Kawau Island – A long span design that shows what is possible with FRP infrastructure
Pushing the boundaries of overhead line design
Kawau Island presented an engineering challenge unlike a conventional distribution line. The project required an overhead span of approximately 746 metres across difficult terrain, demanding careful consideration of conductor loading, structural behaviour and long-term serviceability.
Designed by Vector, the solution utilised Wagners CFT 15 metre FRP utility poles, composite crossarms and an engineered stay system to create what is believed to be the world’s longest span achieved using an FRP utility pole.
The project demonstrates how composite infrastructure can support innovative network design when backed by proven engineering data and rigorous testing.
Engineering confidence through testing
Long-span applications demand more than strong materials.
Before the Kawau Island project was ever conceived, Wagners CFT had invested in extensive testing to better understand the behaviour of its FRP utility pole system, including bending performance, connection behaviour, stiffness, washer pull-through and stay wire interaction.
This engineering validation provided designers with the confidence to apply composite infrastructure to one of the most demanding overhead line applications undertaken to date.
By combining innovative design with independently validated performance data, the project demonstrates what becomes possible when engineering leads decision-making.
Lightweight infrastructure for challenging environments
Remote and difficult-access locations often present significant construction challenges.
The lightweight nature of FRP utility poles simplifies transportation and installation while providing long-term corrosion resistance and durability in harsh environments.
Combined with their excellent strength-to-weight ratio, Wagners CFT’s composite utility poles continue to open new possibilities for projects where traditional materials may introduce construction or logistical constraints.
More than a record span
While the approximate 746 metre span is a remarkable engineering achievement, the project’s greatest significance lies in what it demonstrates for the future of electricity networks.
Kawau Island shows how technically validated composite infrastructure can help utilities rethink what is possible in challenging environments, supporting innovative overhead line design without compromising structural performance or long-term reliability.
As utilities continue to face increasingly complex network challenges, projects like this provide confidence that new engineering solutions are available when supported by proven testing and sound design.
