PUPI Products & Technical Specifications

PUPI manufactures a complete line of fiberglass-reinforced polymer products for overhead utility distribution and transmission. Every product is manufactured using a pultrusion process that delivers consistent, predictable strength—available in standard RUS patterns or custom specifications, with no additional lead time for custom drill patterns.

Distribution Product Line

PUPI fiberglass tangent crossarm centermount configuration on wood pole

Tangent Crossarms

The core of PUPI’s distribution offering. Available in centermount, braced, and alley arm applications.

PUPI tangent crossarms are the direct composite replacement for wood in standard pole line builds. They weigh significantly less than wood—with up to six times the strength. A closed-cell polyurethane foam fill provides lightweight, field-drillable stability that also prevents moisture and contamination from entering the crossarm.

Available in the TB1000, TB2200, TB2000, TB2500, and TB3000 series, with load capacities ranging from 1,000 to 5,000 lbs per wire depending on configuration. Designed for custom specifications or standard RUS patterns, tested per ASTM-8019.

Available in Canada through Rexel Utility. Standard and custom configurations ship to all provinces.

Tangent Crossarm Load Data

Standard RUS patterns — tested per ASTM-8019

ConfigurationTB1000TB2200TB2000TB2500TB3000InchesRUS Pattern
4-Wire — Load Capacity per Wire1,500 LB
29 LBS		2,250 LB
34 LBS		3,500 LB
41 LBS		3,500 LB
42 LBS		5,000 LB
56 LBS		09603X
6-Wire — Load Capacity per Wire1,000 LB
29 LBS		1,500 LB
34 LBS		2,250 LB
41 LBS		2,500 LB
42 LBS		3,250 LB
57 LBS		09604X
6-Wire — Load Capacity per Wire—1,500 LB
39 LBS		2,250 LB
48 LBS		2,250 LB
49 LBS		3,250 LB
65 LBS		12005X
4-Wire — Load Capacity per Wire——3,250 LB
54 LBS		3,500 LB
55 LBS		5,000 LB
73 LBS		144—

Load values shown per wire. Assembly weight in LBS shown below each load value. Custom drill patterns available — contact Rexel Utility for a specification worksheet.

PUPI fiberglass deadend assembly installed on distribution pole

Deadend Assemblies

Engineered to outperform and outlast wood in high-load termination and angle applications.

PUPI deadend assemblies are built for the highest mechanical demands on the line. With proven performance in every climate, they provide high strength and uniformity for the most reliable deadend available. Delivered fully assembled to customer drill specifications, ready to install.

Available in the DA2000, DA2500, DA3000, DA3020, and DA4000 series. Longitudinal ultimate loads range from 5,500 to 32,000 lbs per wire depending on series and configuration. PUPI offers the largest selection of RUS-accepted deadend assemblies in the industry.

Available in Canada through Rexel Utility. Standard and custom configurations ship to all provinces.

Deadend Assembly Load Data

Longitudinal ultimate load per wire — tested per ASTM-8019

ConfigurationDA2000DA2500DA3000DA3020DA4000InchesRUS Pattern
2-Wire — Ultimate Load per Wire9,500 LBS
53 LBS		11,000 LBS
54 LBS		16,000 LBS
62 LBS		32,000 LB
115 LBS		20,000 LB
80 LBS		096E2B7X
4-Wire — Ultimate Load per Wire5,500 LB
63 LBS		6,000 LB
70 LBS		10,000 LB
72 LBS		20,000 LB
135 LBS		11,750 LB
98 LBS		096E4B7X
2-Wire — Ultimate Load per Wire7,250 LBS
60 LBS		8,250 LBS
61 LBS		14,500 LBS
71 LBS		29,000 LBS
132 LBS		20,000 LBS
91 LBS		120E2B9X
4-Wire — Ultimate Load per Wire5,500 LBS
68 LBS		6,000 LBS
69 LBS		9,250 LBS
80 LBS		18,500 LBS
151 LBS		11,750 LB
112 LBS		120E4B9X
2-Wire — Ultimate Load per Wire—6,500 LBS
67 LBS		11,500 LBS
79 LBS		23,250 LBS
150 LBS		17,000 LBS
102 LBS		144E2SPX
4-Wire — Ultimate Load per Wire—4,500 LBS
76 LBS		8,000 LBS
88 LBS		15,750 LBS
168 LBS		11,500 LBS
125 LBS		144E4SPX

Longitudinal ultimate load values shown per wire. Assembly weight in LBS shown below each load value. DA3020 series highlighted — highest ultimate load in the industry at 32,000 LBS per wire (2-wire, 096″). Custom drill patterns available.

PUPI galvanized steel mount with fiberglass X-brace and SunGUARD coating

Mounts & Braces

Structural reinforcement and mounting solutions for complete pole assemblies.

Mounts are welded structural steel, hot dip galvanized to ASTM A123. PUPI fiberglass braces are made from pultruded solid fiberglass profiles with thermally bonded SunGUARD® coating, available in standard and heavy duty. Guy plate supports 30,000 lbs at 30, 45, and 90 degrees.

Center mount kits include front plate, galvanized hardware, with pole mount spacing available in 8″, 10″, and 12″. Deadend mounts feature 2″ double guy attachment spacing with 15/16″ diameter guy attachments rated to 30,000 lbs.

Available in Canada through Rexel Utility. Standard and custom configurations ship to all provinces.

PUPI fiberglass pole top extension with adjustable steel mounting bracket

Pole Top Extensions

A cost-effective alternative to full pole replacement.

PUPI Pole Top Extensions are used to extend the height of existing utility poles or replace damaged pole tops—delivering all the quality and durability features that define the PUPI product line without the cost and labour of a full pole replacement.

Built from lightweight, strong 5″ x 5″ fiberglass beams with an adjustable galvanized steel mounting bracket that installs on pole diameters from 6″ to 10″. Available in 36″, 54″, and 72″ lengths (standard configuration is 54″ at 58 lbs assembly weight). Standard configuration ships without holes—holes can be drilled per customer specifications. Features include:

  • Thermally bonded SunGUARD® UV-resistant coating
  • TorqueGUARD™ reinforced holes on all factory-drilled configurations
  • Sealed, UV-resistant endcap
  • Closed-cell rigid foam fill to exclude moisture and contaminants
  • Field drillable per PUPI usage and installation guidelines
  • Available in gray

Available in Canada through Rexel Utility. Standard and custom configurations ship to all provinces.

Interested in Pole Top Extensions? Click here to read about their application in our Use Cases.

Transmission Product Line

PUPI single crossarm fiberglass H-frame transmission structure

H-Frame Systems

The most comprehensive line of fiberglass transmission crossarms and braces available. PUPI H-frame products are engineered for maximum strength and consistent performance in standard and custom configurations. Available in single crossarm and double crossarm designs.

The Series 5000 transmission crossarm is a one-to-one dimensional replacement for wood, but with dramatically lower weight, twice the strength, and equal stiffness. This allows utilities to use existing industry hardware and installation practices.

Available in Canada through Rexel Utility. Standard and custom configurations ship to all provinces.

Single Crossarm H-Frame

By leveraging the superior strength of fiberglass, single crossarm H-frame designs streamline construction, ease installation, and reduce cost. PUPI single-sided systems have been extensively tested and exceed RUS strength requirements for TH-10 V4 construction by 21%.

Optimized designs reduce assembly weight by over 50% versus traditional double-arm wood construction. A traditional 32’ TH-10 fully braced wood double crossarm assembly weighs around 1,000 lbs; the PUPI equivalent comes in at approximately 447 lbs.

Available in Canada through Rexel Utility. Standard and custom configurations ship to all provinces.

Single Crossarm H-Frame Load Data

Series 5000 — load capacity per wire, 3 wires — tested per ASTM-8019

RUS Frame TypeCrossarm Length (FT)Ultimate Vertical Load (LBS)Assembly Weight (LBS)1Deflection (IN/1,000 LBS)2
TH-12211,5001350.8
TH-1A269,7501581.1
TH-10 V43217,2504470.2
TH-230 V44015,0005150.2
TH-345 V45513,5006450.2

1 Assembly weights do not include X-Braces. Traditional 32′ TH-10, fully braced, wood double crossarm construction weighs around 1,000 LBS — PUPI’s single crossarm design reduces weight by over 50%. 2 TH-1 and TH-1A designs do not include knee-vee braces. Exceeds RUS strength requirements for TH-10 V4 construction by 21%.

Double Crossarm H-Frame

A more traditional style of construction with the added strength of PUPI fiberglass components, providing unmatched strength for ultimate line hardening. Ideal for utilities that prefer conventional double-arm designs with the lifecycle and maintenance advantages of composites.

Available in Canada through Rexel Utility. Standard and custom configurations ship to all provinces.

Transmission-Class Performance

PUPI single-sided systems exceed RUS strength requirements for TH-10 V4 construction by 21%. Optimized single-crossarm designs reduce assembly weight by over 50% versus traditional double-arm wood construction — a 32′ TH-10 fully braced wood double crossarm assembly weighs approximately 1,000 lbs; the PUPI equivalent comes in at approximately 447 lbs. Vertical loads of up to 17,250 lbs per wire (TH-10 V4, 32′ crossarm) are supported across the H-frame line.

Performance You Can Count On

Over 7 million PUPI fiberglass crossarms are in service across North America and globally, in environments ranging from extreme heat to severe cold. There are no documented field failures attributed to environmental degradation across the installed base.

How Does PUPI Fiberglass Compare?

Side-by-side performance across the metrics that matter to utility engineers

Performance MetricPUPI FiberglassWoodSteel
Service Life60+ years proven15–30 years typical30–40 years typical
Strength-to-WeightUp to 6× stronger than wood at significantly less weightBaselineHigh strength, heavy weight
Weight (Distribution Crossarm)29–73 LBS80–150+ LBS120–200+ LBS
Environmental Failure RateZero failures in 35+ yearsRot, UV, wildlife, freeze-thawRust, corrosion, fatigue
UV & Weathering ProtectionSunGUARD® — 60+ year proven coatingChemical treatment (degrades)Galvanizing (degrades over time)
Moisture ResistanceClosed-cell foam — zero absorptionAbsorbs moisture → rot & freeze-thawResistant (but traps condensation)
Bolt-Tightening Torque450+ ft-lbs (TorqueGUARD™ bushings)Limited — wood crushesHigh — but galvanic corrosion risk
Dielectric PropertiesNon-conductive — increased BILConductive when wetFully conductive
Material ConsistencyPultruded — uniform, predictable strengthKnots, grain variation, species-dependentConsistent (manufactured)
Maintenance RequirementInstall and forget — no retreatmentRegular inspection, retreatment, replacementCorrosion monitoring, recoating
Wildlife / Pest DamageImmune — not a food sourceWoodpeckers, insects, fungiImmune
Crew InstallationLighter = smaller crews, faster installHeavy — larger crews requiredHeavy — specialized equipment often needed
Best-in-class across every metricLegacy standardNiche applications

Performance data sourced from PUPI published specifications. Service life based on 35+ years of field deployment and accelerated weathering testing. 7+ million crossarms in service since 1990.

key performance data

Tangent crossarm load capacity: 1,000–5,000 lbs per wire depending on series (4-wire and 6-wire configurations).

Deadend ultimate loads: 4,500–32,000 lbs per wire depending on series and configuration.

Transmission H-frame vertical loads: Up to 17,250 lbs per wire (TH-10 V4, 32’ crossarm).

Strength-to-weight: Up to 6x the strength of wood at significantly less weight.

TorqueGUARD™ bushings: Over 450 ft-lbs bolt-tightening torque without damage.

Dielectric properties: Non-conductive fiberglass provides increased Basic Insulation Level (BIL).

A Three-Layer Weathering Protection System

Every PUPI product starts with pultruded fiberglass-reinforced polymer—continuous glass fibres pulled through a resin matrix under heat and pressure. Three levels of weathering protection come standard:

PUPI fiberglass crossarm cross-section showing SunGUARD coating, closed-cell foam, and resin-rich surface veil layers

LAYER 1

SunGUARD® UV Coating

Thermally bonded to the surface of every PUPI product. Rigorous testing across multiple climates shows SunGUARD® coating maintains effectiveness for at least 60 years, resisting weathering and fibre blooming that causes arc tracking in unprotected composites.

LAYER 2

Closed-Cell Polyurethane Foam

Every crossarm is completely filled with closed-cell sealant to lock out moisture and contaminants. No water absorption means no freeze-thaw damage — a material requirement for Canadian utility deployments across the Prairies, Atlantic, and northern climate zones.

LAYER 3

Resin-Rich Surface Veil

The outer surface of the pultruded profile provides an additional barrier against environmental exposure, working in concert with the SunGUARD® coating and foam core.

Approved Where It Counts

RUS Listed — Largest selection of Rural Utilities Service accepted fiberglass composite crossarm and deadend assemblies in the industry.

Tested per ASTM-8019 — All standard PUPI designs, RUS drill patterns, and custom configurations structurally validated.

ASTM A123 (mounts) — Welded structural steel mounts hot dip galvanized to ASTM A123.

ASTM G-154 / G-155 (UV testing) — Accelerated weathering validated via Q-UV and Q-SUN chamber testing.

On-site test labs — In-house materials lab (DSC, TGA, humidity chamber, UV chambers) and two structural test labs with thousands of documented tests.

Compliance for Canadian Utilities

PUPI fiberglass crossarms are tested and certified to standards recognized by Canadian utilities. All products are tested per ASTM D8019 (Standard Test Methods for Determining the Mechanical Properties of Pultruded Fiberglass Crossarms), which serves as the primary performance benchmark for fiberglass crossarms across both US and Canadian markets.

Canadian utilities evaluating fiberglass composite crossarms can reference PUPI’s RUS-listed configurations as equivalent or exceeding provincial utility construction standards. The same load ratings, material specifications, and environmental performance data used for RUS acceptance apply directly to Canadian distribution and transmission applications.

For utilities requiring CSA or IEEE documentation, Rexel Utility’s technical team can provide application-specific compliance guidance and connect you directly with PUPI’s engineering group for custom configurations.

PUPI fiberglass crossarms installation

System Design Flexibility, On Standard Lead Times

Custom designs and drill patterns do not add to standard lead times. PUPI’s engineering team works directly with customers to create solutions for specific system needs:

  • Standard RUS patterns and custom drill specifications for tangent and deadend crossarms.
  • Centermount, braced, and alley arm configurations for distribution.
  • Single and double crossarm H-frame designs for transmission.
  • Pole top extensions in 36″, 54″, and 72″ lengths with adjustable brackets for 6″–10″ pole diameters.
  • Made-to-order brace lengths in standard and heavy duty.
  • Available in gray and brown.

PLS Pole Library files are available for download for design and engineering use.

Need Specs for Your Application?

Our team can provide detailed product specifications, load data, and configuration guidance for your project.

Find Your Regional PUPI Specialist

Western Canada (BC & Alberta)

Distribution, transmission, and pole top extensions for western utilities. Contact your Rexel Utility western team.

Ontario

Full PUPI product line for Ontario’s distribution and transmission infrastructure. Contact your Rexel Utility Ontario team.

Quebec

Composite solutions for Quebec’s demanding winter conditions. Contact your Rexel Utility Quebec team.

Atlantic Canada

Coastal-rated fiberglass systems for maritime environments. Contact your Rexel Utility Atlantic team.