Industry Overview
Wooden, steel, and concrete poles have been used for power distribution lines since the 19th century, with wooden poles being the earliest type. As demand increased and power lines required longer poles capable of resisting greater horizontal forces, steel poles were introduced as an alternative to wood. Wooden poles have a limited service life, while steel poles generally have a longer life but require continuous maintenance for corrosion protection. Concrete, particularly prestressed concrete, can provide a very long service life with minimal maintenance related to corrosion protection.
Prestressed concrete electric poles are designed primarily to resist horizontal forces generated by wind acting on the pole and the wires it supports. Their cross-sections are therefore designed to provide greater moment resistance in one direction and lower resistance in the perpendicular direction, commonly using rectangular or double-T configurations. Rectangular prestressed concrete poles are designed for both serviceability and strength, considering wire configuration, permissible stresses, working loads, and first-crack loads.
The poles are generally tapered and may incorporate a hollow core to reduce weight, with larger cross-sectional areas provided toward the base where resistance requirements are greatest. Critical design considerations include wind-induced bending, torsion from eccentric or skew wire snapping, wire failure, and handling and erection stresses. The report proposes a greenfield Prestressed Concrete Electric Pole (Rectangular) facility with an installed capacity of 30000 Poles per year and states that the market was projected to grow at a CAGR of 5.0% during 2017 to 2027.
Cost Estimation
| Particulars | Value |
|---|---|
| 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% |
Content Index
- 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
- 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)
Frequently Asked Questions
Prestressed concrete electric poles are structural concrete poles reinforced with tensioned steel to improve their ability to withstand service loads. Prestressing introduces compressive stresses into the concrete, helping the pole resist bending and tensile stresses produced during operation. These poles are commonly designed to withstand wind loads on the pole and supported conductors, as well as torsional and handling stresses. Rectangular configurations can provide different moment capacities in the two principal directions, making them suitable for power distribution applications.
Prestressed concrete poles offer high structural strength, durability, and low corrosion-protection maintenance requirements. Compared with wooden poles, concrete poles can provide a substantially longer service life, while prestressing improves resistance to bending and cracking. The poles can also be tapered and manufactured with hollow cores where appropriate to reduce weight. Their design can be adapted to different loading requirements, wire arrangements, pole lengths, and cross-sectional configurations used in electrical distribution systems.
The principal raw materials include cement, aggregates, prestressing steel, reinforcement, concrete, and admixtures. Cement and aggregates form the primary concrete constituents, while prestressing steel provides the tensioning system responsible for introducing prestress. Reinforcement supports the structural requirements of the pole, and suitable admixtures may be used to achieve required concrete performance. Material selection and quality control should comply with the applicable product, design, and concrete standards specified for the project.
Rectangular prestressed concrete poles are manufactured through a controlled sequence of reinforcement preparation, prestressing, concrete placement, curing, detensioning, cutting, testing, and inspection. The process generally begins with preparing the bed and mould, positioning stirrups and reinforcement, and tensioning the prestressing wires. Concrete is then mixed and placed into the mould, followed by vibration and curing. After the concrete develops the required properties, the wires are detensioned and cut, the poles are removed from the bed, marked, tested, and stored for inspection.
Prestressed concrete poles are subjected to tests that verify their structural performance and manufacturing quality. The report specifically identifies transverse strength testing, measurement of concrete cover, cube testing, and testing of straightness. Transverse strength testing evaluates the pole's ability to resist specified lateral loading and provides information about cracking and failure behaviour. Concrete cube testing helps verify concrete strength, while cover and straightness checks help confirm dimensional and manufacturing requirements before the poles are accepted for use.
A prestressed concrete pole plant requires equipment for concrete production, prestressing, moulding, material handling, curing, testing, and utilities. The report identifies concrete mixers, concrete carrying trolleys, shuttering vibrators, electric pre-stressing machines, winch machines, gantries, electric pump sets, welding sets, transformers, air compressors, trolleys, pole-testing equipment, and sprinkler systems. Depending on the plant configuration, additional facilities can include a concrete batching and mixing plant, laboratory testing equipment, material handling equipment, and a DG set.
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