Custom Engineered Transmission and Substation Structures

As the demand for reliable power grows across the United States, the backbone of our electrical grid—transmission and substation structures—requires innovation, customization, and engineering precision. At Smith Industries, we specialize in custom engineered transmission and substation structures, offering solutions that support voltages up to 500kV and meet the highest industry standards.

Whether you're working on a greenfield project, upgrading aging infrastructure, or expanding to meet new regulatory requirements, having a partner with the engineering capability, manufacturing expertise, and national reach is essential. Smith Industries stands ready to support energy infrastructure across the country with structures tailored for strength, durability, and efficiency.

Designing for Up to 500kV: Meeting High-Voltage Needs

Transmission and substation structures are the skeletons that support high-voltage electrical lines and equipment, transferring power over vast distances. The scale of these systems means that even minor structural shortcomings can pose serious risks. Our custom engineering team is equipped to design structures that safely carry voltages up to 500kV, addressing both mechanical stress and electrical performance.

By accounting for factors such as conductor tension, wind load, seismic activity, and extreme temperatures, we engineer each structure for optimal field performance. Every design is modeled with real-world data to provide long-term stability and operational confidence.

Comprehensive 50-State P.E. Stamping: Coast-to-Coast Compliance

Regulatory compliance is a critical component of infrastructure development. Each state in the U.S. has specific codes and requirements for construction and engineering practices. Smith Industries provides 50-state P.E. stamping of calculations and drawings, giving our clients confidence that their projects will meet the required standards no matter where they are located.

Our team works closely with licensed Professional Engineers (P.E.s) in every state to verify that each design satisfies local regulations. This capability streamlines project approvals, shortens lead times, and reduces costly design modifications during the permitting phase.

Custom Structures for Unique Project Demands

Every transmission and substation project comes with its own set of challenges: terrain, climate, grid connection points, and evolving industry standards. That’s why off-the-shelf solutions often fall short. Our in-house team at Smith Industries collaborates with utility companies, EPC firms, and grid operators to develop custom solutions that meet the specific parameters of each job.

From dead-end structures and A-frame configurations to substation gantries and switch stands, each product is designed to fit the exact layout and mechanical requirements of the site. We leverage advanced 3D modeling tools and structural analysis software to reduce material usage while maximizing strength and longevity.

Supporting a Resilient National Grid

Custom engineered structures are not just about customization; they’re about national resilience. The U.S. Department of Energy highlights that improving transmission infrastructure is vital to enhancing grid reliability and meeting clean energy goals. According to Energy.gov, modernizing and expanding the nation’s grid requires innovative infrastructure solutions that can accommodate increasing demand and incorporate more renewable energy.

Substation and transmission structures must support this expansion while withstanding more frequent extreme weather events. Custom engineering allows us to factor in these stressors, protecting critical infrastructure from outages and minimizing downtime.

Material Expertise and Fabrication Strength

Smith Industries has deep experience working with materials like galvanized steel, high-strength alloys, and corrosion-resistant coatings. Whether a project calls for lattice towers, tubular steel poles, or customized switch frames, our team builds it to exacting standards.

We also consider transportation and constructability early in the design process. Modular components and prefabricated structures save time on-site and reduce the need for specialized labor, a crucial advantage in today’s tight labor market.

Safety and Standards: Built Into Every Design

All Smith Industries structures comply with industry-recognized codes such as the National Electrical Safety Code (NESC) and relevant ASCE standards. Designs are reviewed for electrical clearance, grounding compatibility, and safe access for maintenance teams. Safety isn't just a consideration; it's foundational to how we build and think.

Furthermore, substation structures are increasingly subject to scrutiny regarding physical security and protection from high-impact events. By designing with these concerns in mind, our products support evolving utility needs and security protocols.

A Partner for Energy Providers, EPCs, and Utilities

From early-stage planning and design to stamped drawings and delivery logistics, Smith Industries offers full-service support. We understand the urgency of energy infrastructure projects and operate with a sense of ownership that drives us to meet tight timelines and exacting specifications.

As utilities and transmission operators face pressure to modernize systems and meet clean energy mandates, Smith Industries provides a dependable, scalable solution. We are proud to be part of the national effort to strengthen and expand the electrical grid.

Final Thoughts: Building the Future of Power Infrastructure

Custom engineered transmission and substation structures play a critical role in supporting the reliability and advancement of the American power grid. With voltages reaching up to 500kV and regulations varying state by state, choosing a partner who offers design precision, national compliance, and fabrication excellence is more important than ever.

As noted by the Federal Energy Regulatory Commission (FERC), modernizing the transmission grid is essential to maintain affordability, reliability, and security. Smith Industries stands at the intersection of engineering, manufacturing, and grid modernization, delivering structures that meet today’s needs and anticipate tomorrow’s challenges.

To learn more about how Smith Industries can support your next transmission or substation project, contact our engineering team or explore our full suite of custom fabrication capabilities.