Detailed Project Report (DPR) on Prestressed Concrete Poles (PSC Poles)

PRESTRESSED CONCRETE POLES (PSC POLES)

[EIRI/EDPR/1534] J.C.328 (US$) 518 (INR)

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.

Though both materials are still in use throughout the world, with wood primarily used for short length small forces country lines the general trend is to substitute both the materials with concrete and Use reinforced and prestressed concrete poles instead.

Wooden 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. Experience however has shown that concrete poles with a circular cross section are preferable to poles with rectangular or T section as they resist better impact loads and little extra cost give the added advantage that they have an equal resistance to horizontal forces in all direction. The circular cross section besides the advantage mentioned earlier lends itself to very well to use for the manufacture of poles of the spinning process. As well known the spinning process is one of the best methods of casting freshly cast concrete, as the centrifugal forces applied to concrete, secure a dense, excellent quality concrete at relatively less manufacturing costs. The pre stressed hollow or tubular pole have proved to be more economical, easily transported and erected due to lightweight.

COST ESTIMATION (US$ DOLLOR)

Plant Capacity                                             117.00 Nos/Day                  
 Land & Building (16000 Sq.Mtr)               US$ 10.60 Lacs
Plant & Machinery                                       US$ 10.89 Lacs         
W.C. for 2 Months                                        US$ 5.56  Lacs          
Total Capital Investment                             US$ 27.55 Lacs              
Rate of Return                                             35%   
Break Even Point                                        59%

CONTENTS

INTRODUCTION

USES OF SPUN CONCRETE POLE OTHER THAN TRANSMISSION AND DISTRIBUTION LINE

QUALITY STANDARDS

SPECIAL REPORT – EQUIPMENT

USE OF READY-MIX CONCRETE (RMC)

POLE-TESTING EQUIPMENT

MARKET SURVEY

PRESTRESSED CONCRETE ELECTRIC POLES

THE MANUFACTURE OF TUBULAR PSC POLES CONSISTS OF THE FOLLOWING OPERATION:

CURING SYSTEM FOR PSC POLE

REQUIREMENT OF BATCHING PLANT

PRINCIPLE AND MANUFACTURING TECHNOLOGY OF CONCRETE SPUN POLE OULDS

DESIGN OF PSC POLES

SUPPLIERS OF PLANT AND MACHINERY

ROUND PRESTRESSED ELECTRIC CONCRETE POLE STEEL

MOULD 9M 10M 11M

SUPPLIERS OF MACHINERY

SUPPLIERS OF RAW MATERIALS

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)