Detailed Project Report on PRODUCTION OF PRESTRESSED CONCRETE ELECTRIC POLE (RECTANGULAR)

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.

1. www.eiribooksandprojectreports.com 1

ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org



PRODUCTION OF PRESTRESSED CONCRETE
ELECTRIC POLE (RECTANGULAR)
[CODE: EIRI/EDPR/4699] J.C.: 2918US$


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.

2. www.eiribooksandprojectreports.com 2



Need for Prestressing Concrete

Concrete has a poor tensile strength and a great compressive strength. This is a
concrete weakness that causes early flexural cracks in flexural components such
as beams and slabs. Compressive stress is induced in the concrete to prevent this.
Prestressing is a stress that counteracts the tensile stress that the structure is
subjected to while in service. Hence the chances of flexural cracks are reduced.

History of Electric Pole

For many years throughout the world, Poles made of wood, steel and concrete
have been used to support power transmission, telephone and telegraph lines,
street lighting, overhead power lines for rail-roads and other many purpose used
pole. The application of permanent compressive stress to a material like concrete,
which is strong in compression but weak in tension, increases the tensile strength
of that material. In 1904, French engineer Freyssinet attempted to introduce
permanently acting forces in concrete to resist the elastic forces developed under
loads and this idea was later developed under the name of “Prestressing”. The
current status of prestressed concrete development is the result of ongoing study
by engineers and scientists in the area over the last 90 years.

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:

3. www.eiribooksandprojectreports.com 3

CONTENTS

INTRODUCTION 9
NEED FOR PRESTRESSING CONCRETE 10
HISTORY OF ELECTRIC POLE 10
A WIRE DIAMETER IS CHOSEN. 11
ADVANTAGES/APPLICATI ONS 14
APPLICATIONS OF PRESTRESSED CONCRETE POLES 14
APPLICATIONS OF PRESTRESSED CONCRETE POLES 15
B.I.S. SPECIFICATIONOF PRODUCTS 16
MARKET OVERVIEW 18
PRESTRESSED CONCRETE MARKET DEFINITION 18
PRECAST CONCRETE POLE MARKET SIZE 19
MARKET DYNAMICS 19
PRESTRESSED CONCRETE MARKET SHARE BY REGI ON 2022 (%) 20
PRESTRESSED CONCRETE MARKET MAJOR PLAYERS ARE: 20
THREE METHODS ARE GENERALLY USED TO MANUFACTURING
OF PRESTRESSED CONCRETE POLE AND THEY ARE 21
CENTRIFUGAL CASTING METHOD 21
LONG LINE METHOD 22
MENSEL’S METHOD 23
DESIGN OF PSC CIRCULAR SPUN POLE OF 8 METER LONG 24
CALCULATION FOR WIND PRESSURE AS PER IS: 875 PART -3 25
ASSUMPTION 26
STRESS IN DIRECTION OF LINE 27
DRAWING OF PSC CIRCULAR SPUN POLE OF 8 METER LONG 29
TOP AND BOTTOM VIEW 29
SIDE VIEW 30
TERMINOLOGY: 30
AVERAGE PERMANENT LOAD: 30
LOAD FACTOR: 30
TRANSVERSE: 31
TRANSVERSE LOAD AT FIRST CRACK: 31
WORKING LOAD: 31
ULTIMATE FAILURE: 31
ULTIMATE TRANSVERSE LOAD: 31
OVERALL LENGTH OF POLE: 31

4. www.eiribooksandprojectreports.com 4
TOLERANCES: 32
TEST OF STRAIGHTNESS OF POLE: 32
THE COMPOSITION OF PRESTRESSED CONCRETE (PSC) POLE
IS CONSIDERED AS FOLLOWS: 32
RAW MATERIALS (FOR PRESTRESSED CONCRETE POLE) 33
CEMENT 33
AGGREGATES 33
PRESTRESSING STEEL 33
REINFORCEMENT 34
CONCRETE 34
ADMIXTURE 34
QUALITY STANDARDS 34
DESIGN SPECIFICATION OF PRESTRESSED CONCRETE POLE 34
DEPTH OF PLANTING 35
TRANSVERSE STRENGTH AT FAILURE 36
DESIGN REQUIREMENTS FOR PRESTRESSED CONCRETE POLE 37
DESIGN OF PRESTRESSED CONCRETE POLE (GUI DELINES) 38
SHAPE 38
MANUFACTURING STEPS - PRESTRESSED CONCRETE POLE 39
BED & MOULD 39
STIRRUPS 39
PREPARATION OF REINFORCEMENT 39
CONCRETE MIX 40
PLACING OF CONCRETE MIX 40
DETENSIONING, CUTTING OF WIRE & REMOVING OF POLES FROM BED 41
CURING 41
STORING OF POLES READY FOR INSPECTION 41
MARKING 41
CUBE TESTING 42
PROCESS FLOW DIAGRAM 47
TESTING METHOD FOR PRESTRESSED CONCRETE POLE 49
TRANSVERSE STRENGTH TEST 49
MEASUREMENT OF COVER 50
PRE CAST CONCRETE COMPONENTS & EQUIPMENT S 51
PRE-STRESSED COMPONENTS 51
PRE-STRESSED CONCRETE POLES 51
SIZE OF POLES 51
EQUIPMENT FOR MANUFACTURING 52

5. www.eiribooksandprojectreports.com 5
THE EQUIPMENTS REQUI RED FOR A POLE WORKSHOP ARE: 52
CONCRETE MIXERS 53
CONCRETE CARRYING TROLLEYS 53
USE OF READY-MIX CONCRETE (RMC) 53
SHUTTERING VIBRATORS 54
ELECTRIC PRE-STRESSING MACHINES 56
WINCH MACHINES 57
GANTRIES 58
ELECTRIC PUMP SETS 58
WELDING SETS 58
TRANSFORMERS 59
AIR COMPRESSORS 59
TROLLEYS 59
POLE-TESTING EQUIPMENT 59
SPRINKLER SYSTEM 60
QUICK BYTES 60
SUPPLIERS OF MAJOR PLANT & MACHINERY 61
MACHINERY 61
BOILERS 61
MATERIAL HANDLING EQUIPMENTS 62
LABORATORY TESTING EQUIPMENTS 63
CONCRETE BATCHING & MIXING PLANT 63
SUPPLIERS OF PLANT AND MACHINERIES (IMPORTED) 64
PRECAST ELECTRIC POLE MACHINE MANUFACTURE 64
SUPPLIERS OF RAW MAT ERIALS 67
CEMENT 67
STEEL WIRES 67
OTHER PLANT & MACHINERY MANUFACTURERS 70
SUPPLIERS OF INTENSIVE SAND MIXTURE AND MULLER 72
SUPPLIERS OF SAND SI EVING MACHINE 75
SUPPLIERS OF MOLDING BOXES 78
SUPPLIERS OF METAL T ESTING MACHINE 79
SUPPLIERS OF PRECISION MEASURING TOOLS 80
SUPPLIERS OF PRECISION MEASURING TOOLS 81
SUPPLIERS OF NDT INSPECTION EQUIPMENT 83
SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES 84
SUPPLIERS OF EOT CRANE 86
SUPPLIERS OF POWER T RANSFORMERS 88

6. www.eiribooksandprojectreports.com 6
SUPPLIERS OF ELECTRI CAL PANEL 90
SUPPLIERS OF ELECTRI C MOTOR 92
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS 93
SUPPLIERS OF PLATFORM WEIGHING MACHINE 95
SUPPLIERS OF MATERIAL HANDLING EQUIPMENT S 96
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS 98
SUPPLIERS OF JIGS AND FIXTURE 99
PRINCIPLES OF PLANT LAYOUT 104
MAJOR PROVISIONS IN ROAD PLANNING FOR MU LTIPURPOSE SERVICE A RE: 108
PLANT LOCATION FACTORS 109
PRIMARY FACTORS 109
1. RAW-MATERIAL SUPPLY: 109
2. MARKETS: 109
3. POWER AND FUEL SUPPLY: 109
4. WATER SUPPLY: 109
5. CLIMATE: 110
SPECIFIC FACTORS 110
6. TRANSPORTATION: 110
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES 110
7. WASTE DISPOSAL: 110
8. LABOR: 110
9. REGULATORY LAWS: 111
10. TAXES: 111
11. SITE CHARACTERISTICS: 111
12. COMMUNITY FACTORS: 112
13. VULNERABILITY TO WARTIME ATTACK: 112
14. FLOOD AND FIRE CONTROL: 112
EXPLANATION OF TERMS USED IN THE PROJECT REPORT 113
1. DEPRECIATION: 113
2. FIXED ASSETS: 113
3. WORKING CAPITAL: 113
4. BREAK-EVEN POINT: 113
5. OTHER FIXED EXPENSES: 113
6. MARGIN MONEY: 114
7. TOTAL LOAD: 114
8. LAND AREA/MAN POWER RATIO: 114
PROJECT IMPLEMENTATI ON SCHEDULES 115
INTRODUCTION 115

7. www.eiribooksandprojectreports.com 7
PROJECT HANDLING 115
PROJECT SCHEDULING 116
PROJECT CONSTRUCTION SCHEDULE 116
TIME SCHEDULE 117
GENERATION AND MANAGEMENT OF WASTES 118
SOLID WASTES 118
LIQUID WASTES 118
GASEOUS EMISSION 118
OTHERS 118
INDUSTRIAL WASTE MANAGEMENT 118
SEWERAGE SYSTEM 118
ANTICIPATED ENVIRONMENTAL IMPACTS 119
CONSTRUCTION PHASE 119
OPERATION PHASE 120
MITIGATION MEASURES (PROPOSED) 120
HEALTH SAFETY & ENVI RONMENT 121
SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING
OF RAW MATERIAL & PRODUCT) 122
SAFETY DATA SHEETS 122
ENVIRONMENTAL/SAFETY LIABILITY 123
PRE-PROJECT ACTIVITIES 124
PROPOSED IMPLEMENTAT ION SCHEDULE 125
PROJECT FINANCIALS 126
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS) 126
CONCLUSIONS: 126
PLANT LAYOUT 127
STATUTORY APPROVALS FROM GOVERNMENT 128
DOCUMENTS REQUIRED FOR LICENSES 129
LIST OF DOCUMENTS: 129
SWOL ANALYSIS 130
STRENGTHS 130
OPPORTUNITIES 130
WEAKNESS 131
LIMITATIONS 131
ORGANIZATION CHART 132
IMPLEMENTATION SCHEDULE 133
PROPOSED IMPLEMENTAT ION SCHEDULE 24 MONT HS 133

8. www.eiribooksandprojectreports.com 8



APPENDIX – A

01. PLANT ECONOMICS A-1
02. LAND & BUILDING A-2
03. PLANT AND MACHINERY A-3
04. OTHER FIXED ASSESTS A-4
05. FIXED CAPITAL A-5
06. RAW MATERIAL A-6
07. SALARY AND WAGES A-7
08. UTILITIES AND OVERHEADS A-8
09. TOTAL WORKING CAPITAL A-9
10. TOTAL CAPITAL INVESTMENT A-10
11. COST OF PRODUCTION A-11
12. TURN OVER/ANNUM A-12
13. BREAK EVEN POINT A-13
14. RESOURCES FOR FINANCE A-14
15. INSTALMENT PAYABLE IN 5 YEARS A-15
16. DEPRECIATION CHART FOR 5 YEARS A-16
17. PROFIT ANALYSIS FOR 5 YEARS A-17
18. PROJECTED BALANCE SHEET FOR (5 YEARS) A-18

9. www.eiribooksandprojectreports.com 9


COST ESTIMATION

Plant Capacity 100 Nos./Day

Land & Building (10,000 sq.mt.) US$ 1.34 Lac

Plant & Machinery US$ 2.53 Lac

Working Capital for 3 Months US$ 6.88 Lac

Total Capital Investment US$ 11.19 Lac

Rate of Return 59%

Break Even Point 55%