Detailed Project Report (DPR) on prestressed concrete (psc) pole (100 Poles/Day)

PRESTRESSED CONCRETE (PSC) POLE

[CODE NO.4443] 

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 for electrical H.T. and L.T. lines widely used now a days in different power distribution in the villages specially rather than towns. Furnish and install prestressed concrete poles for services pole applications, luminaire support, and strain poles for span wire support of traffic signals, signs, and other devices. Basically all the ingredients for the manufacturing of pre stressed concrete poles are available indigenously in our country. All the plant and machineries are available in India. There is no environmentally pollution problem arises in this industry. 

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 readth of pole is determined. The depth of pole cross-section is determined at ground level limiting the compressive and the tensile stresses,  eveloped 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 Pole (Rectangular) facility with an installed capacity of 30000 

Poles per year as a Brown Field Project.

COST ESTIMATION

Plant Capacity                            100 Poles/Day  

Land & Building (8250 sq.mt.)    Rs. 6.46 Cr    

Plant & Machinery                            Rs. 1.91 Cr 

Working Capital for 0.5 Month    Rs. 23.96 Lacs 

Total Capital Investment                  Rs. 8.88 Cr 

Rate of Return                                  11%

Break Even Point                              76%

• • INTRODUCTION
• • ADVANTAGES/APPLICATIONS
• • SPECIFICATION OF PRODUCTS
• • MARKET OVERVIEW
• • FORMULATION/TECHNICAL DATA
• • RAW MATERIALS (FOR PRESTRESSED CONCRETE POLE)
• • DESIGN SPECIFICATION OF PRESTRESSED CONCRETE POLE
• • DESIGN REQUIREMENTS FOR PRESTRESSED CONCRETE POLE
• • DESIGN OF PRESTRESSED CONCRETE POLE (GUIDELINES)
• • MANUFACTURING STEPS - PRESTRESSED CONCRETE POLE
• • TESTING METHOD FOR PRESTRESSED CONCRETE POLE
• • PRE CAST CONCRETE COMPONENTS & EQUIPMENTS
• • SUPPLIERS OF MAJOR PLANT & MACHINERY
• • SUPPLIERS OF RAW MATERIALS
• • GENERATION AND MANAGEMENT OF WASTES
• • SEWAGE AND WASTE WATER EFFLUENT
• • UTILITIES REQUIREMENT (ESTIMATED - MONTH)
• • ANTICIPATED ENVIRONMENTAL IMPACTS
• • MITIGATION MEASURES (PROPOSED)
• • HEALTH SAFETY & ENVIRONMENT
• • SAFETY & OCCUPATIONAL MEASURE
• • ENVIRONMENTAL/SAFETY LIABILITY
• • PRE-PROJECT ACTIVITIES
• • PROPOSED IMPLEMENTATION SCHEDULE
• • PROJECT FINANCIALS
• • PRINCIPLES OF PLANT LAYOUT
• • PRELIMINARY LAYOUT
• • CONCLUSIONS

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)