The Hidden Cost of Traditional Pole Testing

Why “cheap” testing often leads to expensive mistakes

When it comes to maintaining the safety and reliability of utility infrastructure, power pole testing is non-negotiable. But not all testing methods — or providers — are created equal.

Across the United States, many utilities rely on traditional pole testing services because they appear inexpensive upfront. These companies often promise low-cost inspections, sending crews into the field armed with hand tools, hammers, and decades of “experience.”

But what many utilities don’t realize is that the traditional model is designed to upcharge — and it can cost you far more than you bargained for.

The Problem with Subjective Testing

Traditional pole inspections rely heavily on an employee’s judgment:

• Is that hollow sound deep enough to fail the pole?

• Is surface rot a sign of structural compromise or just cosmetic damage?

• Does the inspector’s recommendation lean toward caution — or profit?

This subjectivity creates inconsistent data, often varying from one inspector to the next, and from one circuit to another.

And here’s the kicker: many of these companies incentivize their field teams to “find” bad poles. Why? Because the initial test might be cheap, but the real money comes from treatments, fumigants, wraps, or full replacements they can sell after flagging those poles.

The High Cost of “Cheap”

This approach creates three costly problems for utilities:

1. Unnecessary replacements – Serviceable poles are prematurely removed, eating up replacement budgets.

2. Inflated maintenance costs – Poles that could have been safely monitored are billed for expensive treatments.

3. Bad data – Asset management systems are filled with inconsistent, non-auditable records that can’t stand up to regulatory scrutiny.

What looks like a cost-saving decision upfront often ends up costing utilities hundreds of thousands — or even millions — over time.

A Better Way: Objective, Auditable Data

At Burke Pole Testing, we’ve eliminated the guesswork. Using the THOR Poletest™ system, every pole is assessed in under 60 seconds with non-destructive technology that measures actual structural integrity — not surface symptoms or subjective judgment.

The result? An objective Pole Health Index (PHI™) for every pole, complete with GPS coordinates, and GIS-ready data for easy integration.

And because we don’t sell chemical treatments or replacement services, there’s no financial incentive to exaggerate risk. The data tells the story — and you can trust it.

The Proof Is in the Numbers

Across hundreds of projects across the globe, THOR data shows that roughly 30% of poles flagged for removal are actually serviceable.

That means if you test 100 poles slated for replacement:

• ~30 remain safe and reliable

• At $10,000 per pole, that’s $300,000 saved — minus only a fraction for testing

With clear, auditable data, utilities can:

• Prioritize real risks

• Reinvest budget into true critical replacements

• Build defensible asset management plans that withstand regulatory review

Rethink Your Testing Strategy

Utilities today are under pressure to do more with less. Relying on subjective testing tied to treatment upcharges is a model that belongs in the past.

Objective, auditable, and fast testing isn’t just smarter — it’s more responsible for your ratepayers, your crews, and the communities you serve.

If you’d like to see how a 100 to 500-pole pilot could reshape your replacement plan — and your budget — let’s talk.