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Rethinking Transmission Wire Measurement with Remote Sensing and Photogrammetry

For decades, utilities have relied on mechanical calipers to measure transmission wire diameters. However, this approach requires survey crews to either climb transmission towers or maneuver heavy bucket trucks into energized zones, creating significant safety risks, operational challenges, and environmental impacts to sensitive transmission corridors.

In response, a utility client challenged our team to develop an alternative approach that met several strict requirements:

  • We had to collect measurements remotely with no physical contact with the wire.
  • The process could not rely on small unmanned aerial vehicles (sUAVs).
  • Field teams needed actionable data before leaving the site, eliminating the need for office-based post-processing.

A New Model for Infrastructure Data Collection

To solve this complex infrastructure challenge, we leveraged a multidisciplinary approach backed by our firm’s national resources. Surveyors, photogrammetrists, geographic information system (GIS) specialists, and software developers collaborated to develop a digital-first alternative that met the client’s requirements.

Our framework combines a ground-based, high-resolution camera, a telephoto lens, and traditional survey equipment to accurately measure distances. These tools collect raw field data, which then feeds into a sophisticated software package that our team developed in-house. Using proprietary algorithms, the software computes the precise wire diameters, completely removing the need for physical contact with the electrical infrastructure. 


From Field Challenges to Measurable Results

Over a three-year period, we implemented this technology across every transmission line and substation in our client’s inventory. The deployment yielded quantifiable benefits:

  • Elevated safety: By eliminating the need for tower climbs and bucket truck operations, field crews remain safely on the ground, reducing exposure to high-voltage hazards.
  • Minimal operational downtime: Because our system relies on optical imagery, teams can collect data while lines remain energized, avoiding unnecessary circuit shutdowns.
  • Decreased environmental footprint: Using a ground-based camera and survey array instead of heavy machinery reduces the impact of field activities on environmentally sensitive transmission corridors.
  • Improved accuracy and speed: Our framework delivers highly accurate wire diameter measurements and can even identify individual conductor strands. On-site image processing provides actionable results before crews leave the field.

Building Internal Capability for Long-Term Success

A successful engineering solution should ultimately empower the end user. Following the system’s introduction, we initiated a year-long technology transfer phase to train the client’s internal staff on the specific methodologies and procedures. Through a software licensing model, the client can now independently operate the application for routine measurement activities, and our team continues to provide crucial advisory support. This approach allows the utility to scale its asset management program independently, reducing reliance on outsourced services.

Formalizing an Innovative Approach

To protect the intellectual property, we secured a U.S. patent for the process and software. The patent recognizes the unique approach of translating ground-based optical imagery and distance measurements into an automated, non-contact measurement tool.

By rethinking how we capture field data, our methodology helps utilities improve safety, reduce operational disruption, and obtain highly accurate data without physical contact with energized assets.