PRODUCTION OF PRESTRESSED CONCRETE ELECTRIC POLE (RECTANGULAR)
[CODE: EIRI/EDPR/4699] J.C.: 2918US$
INTRODUCTION
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.
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:
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%
CONTENTS
INTRODUCTION
NEED FOR PRESTRESSING CONCRETE
HISTORY OF ELECTRIC POLE
A WIRE DIAMETER IS CHOSEN.
ADVANTAGES/APPLICATIONS
APPLICATIONS OF PRESTRESSED CONCRETE POLES
APPLICATIONS OF PRESTRESSED CONCRETE POLES
B.I.S. SPECIFICATIONOF PRODUCTS
MARKET OVERVIEW
PRESTRESSED CONCRETE MARKET DEFINITION
PRECAST CONCRETE POLE MARKET SIZE
MARKET DYNAMICS
PRESTRESSED CONCRETE MARKET SHARE BY REGION 2022 (%)
PRESTRESSED CONCRETE MARKET MAJOR PLAYERS ARE:
THREE METHODS ARE GENERALLY USED TO MANUFACTURING
OF PRESTRESSED CONCRETE POLE AND THEY ARE
CENTRIFUGAL CASTING METHOD
LONG LINE METHOD
MENSEL’S METHOD
DESIGN OF PSC CIRCULAR SPUN POLE OF 8 METER LONG
CALCULATION FOR WIND PRESSURE AS PER IS: 875 PART-3
ASSUMPTION
STRESS IN DIRECTION OF LINE
DRAWING OF PSC CIRCULAR SPUN POLE OF 8 METER LONG
TOP AND BOTTOM VIEW
SIDE VIEW
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:
THE COMPOSITION OF PRESTRESSED CONCRETE (PSC) POLE IS CONSIDERED AS FOLLOWS:
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
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
CONCRETE BATCHING & MIXING PLANT
SUPPLIERS OF PLANT AND MACHINERIES (IMPORTED)
PRECAST ELECTRIC POLE MACHINE MANUFACTURE
SUPPLIERS OF RAW MATERIALS
CEMENT
STEEL WIRES
OTHER PLANT & MACHINERY MANUFACTURERS
SUPPLIERS OF INTENSIVE SAND MIXTURE AND MULLER
SUPPLIERS OF SAND SIEVING MACHINE
SUPPLIERS OF MOLDING BOXES
SUPPLIERS OF METAL TESTING MACHINE
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF NDT INSPECTION EQUIPMENT
SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES
SUPPLIERS OF EOT CRANE
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF ELECTRIC MOTOR
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF JIGS AND FIXTURE
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:
SPECIFIC FACTORS
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
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
STATUTORY APPROVALS FROM GOVERNMENT
DOCUMENTS REQUIRED FOR LICENSES
LIST OF DOCUMENTS:
SWOL ANALYSIS
STRENGTHS
OPPORTUNITIES
WEAKNESS
LIMITATIONS
ORGANIZATION CHART
IMPLEMENTATION SCHEDULE
PROPOSED IMPLEMENTATION SCHEDULE 24 MONTHS
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)
