Detailed Project Report (DPR) on production of prestressed concrete electric pole (rectangular)

PRODUCTION OF PRESTRESSED CONCRETE ELECTRIC POLE (RECTANGULAR)

[CODE NO.4218]  

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.

COST ESTIMATION

Plant Capacity                               100 Poles/Day

Land & Building (10,800 sq.mt.) Rs. 3.62 Cr

Plant & Machinery                        Rs. 2.61 Cr

Working Capital for 1 Month      Rs. 51 Lac

Total Capital Investment            Rs. 6.97 Cr

Rate of Return                              17%

Break Even Point                         71%

• 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)