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Is it that expensive? In terms of raw materials it may cost more, but not double. The use of prefabricated parts (torso, limbs) reduces each tower's uniqueness and therefore complexity of repairs. Fabrication of unique beams is well within the repair capability of a mobile crew. Is the actual material cost of each tower a major component of a transmission line cost model? I am betting no; transmission wire, ongoing maintenance, land and rights acquisition, and monitoring probably make up the bulk of a transmission line's cost. Finding actual data on this is proving to be difficult, however.

You're preaching to the wrong audience. Not all people understand "engineering" or "maintenance".

Reading comments here is like getting back in time several years ago when it was first submitted. Same comments, different people.

Pylons average about 30 tons each and steel costs $300-$400 per ton. The UK has about 88,000 pylons. If the new design increases the weight by 20%, then material costs alone would be about $2100 each or $168 million to replace them all.