Detailed Project Report (DPR) on Production of Prestressed Concrete Electric Pole (Rectangular) (100 Numbers Per Day)

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)