PRODUCTION OF PRESTRESSED CONCRETE ELECTRIC POLE (RECTANGULAR)

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Wooden, steel and concrete poles were used for power distribution lines since 19th century. The first poles used were wooden poles. When demand for poles increase and as the power lines under construction required longer poles suitable for resisting larger horizontal forces, steel poles were introduced in substitution to wood. Wooden poles have limited life and Steel poles have a longer life compared to wooden poles requires continuous maintenance for protection against corrosion concrete and particularly prestressed concrete poles can be considered as having an unlimited life without maintenance cost for their corrosion protection.

Poles supporting power lines are subjected to relatively small vertical forces and primarily to large horizontal forces at bottom. The horizontal forces at their top are smaller along the axis of the power line and much larger on direction perpendicular to it. As in the perpendicular direction the pole must resist the horizontal forces caused from wind loads against the poles and the wires carried by them.

In view of the difference in the horizontal forces to which a pole is subjected, the original solution given and still adopted by authorities is to give the pole a cross section with larger moment in one direction and smaller one in the direction perpendicular to it like example a rectangular or double T cross section.

Prestressed concrete poles of rectangular type are designed considering both serviceability and safety (strength). For a specified factor of safety and a given concrete grade, a particular type is designed as follows:

? A wire diameter is chosen.

? Various possible configurations (arrangements) of wires are decided, for different number of wires (even numbers only), starting with a minimum value of 8 and maximum of 20. The following pictures show the typical configurations for 12 and 16 numbers of wires.

For a particular configuration of wires, the minimum possible permissible breadth of pole is determined. The depth of pole cross-section is determined at ground level limiting the compressive and the tensile stresses, developed in the extreme fibers of the cross section under the action of the average permanent load(considered equal to forty percent of the working load) and the first crack load (considered equal to the working load) to their respective permissible values. The maximum amount of resistance in a pole is generally required at the base and, so, the maximum cross sectional area is required at the base section. Poles are generally tapered with a hollow core to reduce the weight. For small lengths of up to 10 m length, square or rectangular cross sections are generally provided.

Prestressed concrete poles are generally designed as members with uniform prestress since they are subjected to bending moments of equal magnitude in opposite directions. The poles are generally designed for the following critical load combinations:

a) Bending due to wind load on the cable and on the exposed faces,

b) Combined bending and torsion due to eccentric snapping of wires,

c) Maximum torsion due to skew snapping of wires,

d) Bending due to failure of all the wires on one side of pole, and

e) Handling and erection stresses in the poles

Prestressed Concrete Electric Pole (Rectangular) Market is project to grow at a CAGR of 5.0% during 2017 to 2027.

It is intended to prepare a Feasibility Report to install a Prestressed Concrete Electric Pole (Rectangular) facility with aninstalled capacity of 30000Poles per year as a Green Field Project.

 

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Description

INTRODUCTION
ADVANTAGES/APPLICATIONS
APPLICATIONS OF PRESTRESSED CONCRETE POLES
APPLICATIONS OF PRESTRESSED CONCRETE POLES
B.I.S. SPECIFICATIONOF PRODUCTS
TERMINOLOGY:
AVERAGE PERMANENT LOAD:
LOAD FACTOR:
TRANSVERSE:
TRANSVERSE LOAD AT FIRST CRACK:
WORKING LOAD:
ULTIMATE FAILURE:
ULTIMATE TRANSVERSE LOAD:
OVERALL LENGTH OF POLE:
TOLERANCES:
TEST OF STRAIGHTNESS OF POLE:
MARKET OVERVIEW
BACKGROUND
CURRENT SCENARIO
MARKET SEGMENTATION
REGIONAL ANALYSIS
DEMAND CREATION
KEY PLAYERS
THE KEY MARKET PLAYERS OF GLOBAL PRESTRESSED CONCRETE PRODUCTS ARE:
FORMULATION/TECHNICAL DATA
SOLID RECTANGULAR POLE OF 8 METRE LENGTH / 200KG WORKING LOAD
DESIGN OF PSC OF 8 METERS LONG
RAW MATERIALS (FOR PRESTRESSED CONCRETE POLE)
CEMENT
AGGREGATES
PRESTRESSING STEEL
REINFORCEMENT
CONCRETE
ADMIXTURE
QUALITY STANDARDS
DESIGN SPECIFICATION OF PRESTRESSED CONCRETE POLE
DEPTH OF PLANTING
TRANSVERSE STRENGTH AT FAILURE
DESIGN REQUIREMENTS FOR PRESTRESSED CONCRETE POLE
DESIGN OF PRESTRESSED CONCRETE POLE (GUIDELINES)
SHAPE
MANUFACTURING STEPS – PRESTRESSED CONCRETE POLE (PSC POLE – RECTANGULAR)
BED & MOULD
STIRRUPS
PREPARATION OF REINFORCEMENT
CONCRETE MIX
PLACING OF CONCRETE MIX
DETENSIONING, CUTTING OF WIRE & REMOVING OF POLES FROM BED
CURING
STORING OF POLES READY FOR INSPECTION
MARKING
CUBE TESTING
PROCESS FLOW DIAGRAM
TESTING METHOD FOR PRESTRESSED CONCRETE POLE
TRANSVERSE STRENGTH TEST
MEASUREMENT OF COVER
PRE CAST CONCRETE COMPONENTS & EQUIPMENTS
PRE-STRESSED COMPONENTS
PRE-STRESSED CONCRETE POLES
SIZE OF POLES
EQUIPMENT FOR MANUFACTURING
THE EQUIPMENTS REQUIRED FOR A POLE WORKSHOP ARE:
CONCRETE MIXERS
CONCRETE CARRYING TROLLEYS
USE OF READY-MIX CONCRETE (RMC)
SHUTTERING VIBRATORS
ELECTRIC PRE-STRESSING MACHINES
WINCH MACHINES
GANTRIES
ELECTRIC PUMP SETS
WELDING SETS
TRANSFORMERS
AIR COMPRESSORS
TROLLEYS
POLE-TESTING EQUIPMENT
SPRINKLER SYSTEM
QUICK BYTES
SUPPLIERS OF MAJOR PLANT & MACHINERY
MACHINERY
BOILERS
MATERIAL HANDLING EQUIPMENTS
LABORATORY TESTING EQUIPMENTS
D G SET
CONCRETE BATCHING & MIXING PLANT
SUPPLIERS OF PLANT AND MACHINERIES (IMPORTED)
SUPPLIERS OF RAW MATERIALS
CEMENT
STEEL WIRES
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TOTAL LOAD:
8. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
GENERATION AND MANAGEMENT OF WASTES
SOLID WASTES
LIQUID WASTES
GASEOUS EMISSION
OTHERS
INDUSTRIAL WASTE MANAGEMENT
SEWERAGE SYSTEM
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HEALTH SAFETY & ENVIRONMENT
SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING OF RAW MATERIAL & PRODUCT)
SAFETY DATA SHEETS
ENVIRONMENTAL/SAFETY LIABILITY
PRE-PROJECT ACTIVITIES
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
CONCLUSIONS:
PLANT LAYOUT

APPENDIX – A:

01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

Additional information

Plant Capacity

100 Poles/Day
Land & Building

(10,800 sq.mt.)
Plant & Machinery

US$ 372857
Rate of Return

17%
Break Even Point

71%

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