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Study On Spun Casting Pre-Stressed Concrete Technology & Its Application To Low Cost Utility Pole Production in Sri Lanka
Study On Spun Casting Pre-Stressed Concrete Technology & Its Application To Low Cost Utility Pole Production in Sri Lanka
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Kasurika Dissanayake
University of Moratuwa
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All content following this page was uploaded by Kasurika Dissanayake on 05 June 2015.
Dissanayake D.M.K.W
(100106 G)
University of Moratuwa
Sri Lanka
May, 2015
STUDY ON SPUN CASTING PRE-STRESSED
CONCRETE TECHNOLOGY & ITS APPLICATION TO
LOW COST UTILITY POLE PRODUCTION IN SRI
LANKA
The Research Thesis was submitted in partial fulfilment of the requirements for
the Degree of Bachelor of Science of Engineering
University of Moratuwa
Moratuwa
Sri Lanka
May, 2015
DECLARATION
I declare that this is my own work and this research does not incorporate without
acknowledgement any material previously submitted for a Degree or Diploma in any
other University or institute of higher learning and to the best of my knowledge and
belief, it does not contain any material previously published or written by another person
except where the acknowledgement is made in the text.
Also, I hereby grant to University of Moratuwa the non-exclusive right to reproduce and
distribute my research, in whole or in part in print, electronic or other medium. I retain
the right to use this content in whole or part in future works (such as articles or books).
D.M.K.W. Dissanayake
The above candidate has carried out this research as an undergraduate research for the
partial fulfilment of the Bachelor of Science Degree under my supervision.
……………………………………… Date:
Dr. C. S. Lewangamage
i
ABSTRACT
The commonly used electrical, lighting & telecommunication transmission poles in Sri
Lanka are made out of normally reinforced concrete. Despite the heavy weight and poor
aesthetically pleasing appearance of them, those poles could stand ahead of steel and
wooden poles due to their comparatively low cost and durability. However the rising
material and labour costs in production of normally reinforced concrete poles, urges the
pole production industry to find new low cost alternatives.
In this study, alternative low cost spun-casting poles have been proposed for Sri Lanka
Telecom (SLT) & Ceylon Electricity Board (CEB). It was found that about 20%-40% of
cost saving and about 10% of weight reduction could be archived by using this technology
for the production of utility poles in Sri Lanka.
ii
ACKNOWLEDGEMENT
I would like to extend my heartfelt gratitude to the each person who made my effort on
this research become a success.
First, I would like to thank my research supervisor, Dr. C. S. Lewangamage, for providing
me all the necessary guidance and support at each step to reach my target. Without that
guidance this research would not have been a success.
Then I wish to show my gratitude all the academic staff of the Department of Civil
Engineering at University of Moratuwa, starting from Professor S. M. A. Nanayakkara,
Head of the Department.
My special thank should go to two of my beloved friends in the university, Miss. J.A.M.
Wijeratna and Mr. K.K.G.K. Danushka, for their unconditional support and continuous
encouragement from the beginning to the end of this research.
Finally, I would make this an opportunity to express my gratitude to all the other people
who have given me support, courage and guidance including my family members, friends
and the non-academic staff of the Department of Civil Engineering
D.M.K.W. Dissanayake
iii
TABLE OF CONTENTS
DECLARATION ----------------------------------------------------------------------------------------------------------------- i
ABSTRACT --------------------------------------------------------------------------------------------------------------------- ii
ACKNOWLEDGEMENT ------------------------------------------------------------------------------------------------------ iii
TABLE OF CONTENTS ------------------------------------------------------------------------------------------------------- iv
LIST OF FIGURES ------------------------------------------------------------------------------------------------------------- vi
LIST OF TABLES -------------------------------------------------------------------------------------------------------------- vi
LIST OF EQUATIONS -------------------------------------------------------------------------------------------------------- vii
LIST OF ABBREVIATION -------------------------------------------------------------------------------------------------- viii
INTRODUCTION -------------------------------------------------------------------------------------------------------- 1
1.1 General ------------------------------------------------------------------------------------------------------------ 1
1.2 Background ------------------------------------------------------------------------------------------------------- 1
1.3 Scope--------------------------------------------------------------------------------------------------------------- 1
1.4 Objectives --------------------------------------------------------------------------------------------------------- 2
1.5 Methodology ----------------------------------------------------------------------------------------------------- 2
1.6 Outcomes --------------------------------------------------------------------------------------------------------- 3
1.7 Arrangement of the report ------------------------------------------------------------------------------------ 3
LITERATURE REVIEW ------------------------------------------------------------------------------------------------ 5
2.1 General ------------------------------------------------------------------------------------------------------------ 5
2.2 A brief history of Prestressed Spun Cast Concrete Technology ---------------------------------------- 5
2.2.1 Pre-stressed Concrete Utility Poles ----------------------------------------------------------------------- 5
2.2.2 Spun Cast Concrete Industry ------------------------------------------------------------------------------- 7
2.3 Comparison of Performance with Different Types of Utility Poles ------------------------------------ 8
2.4 Standards and Guidelines ------------------------------------------------------------------------------------- 10
2.4.1 Concrete Materials ------------------------------------------------------------------------------------------ 11
2.4.2 High Strength Reinforcing Steel Strands --------------------------------------------------------------- 12
2.4.3 Shear Reinforcement --------------------------------------------------------------------------------------- 12
2.4.4 Concrete Mixes for Spun-cast Concrete Poles --------------------------------------------------------- 14
2.5 Steam Curing ---------------------------------------------------------------------------------------------------- 14
2.6 Typical Machinery & Equipment in a Spun-cast prestressed pole manufacturing factory ------- 16
2.7 Typical Concrete Poles Failures ----------------------------------------------------------------------------- 20
2.8 Studies done in Sri Lanka ------------------------------------------------------------------------------------- 21
RESEARCH METHODOLOGY ---------------------------------------------------------------------------------------- 23
3.1 Problem identification and selection of Objectives ------------------------------------------------------ 23
3.2 Literature Survey ----------------------------------------------------------------------------------------------- 23
3.3 Case Study and Design ---------------------------------------------------------------------------------------- 23
iv
3.4 Cost Calculations ----------------------------------------------------------------------------------------------- 24
3.5 Conclusion ------------------------------------------------------------------------------------------------------- 24
DESIGN OF PRESTRESSED SPUN CAST POLES ------------------------------------------------------------------ 25
4.1. Design Criteria --------------------------------------------------------------------------------------------------- 25
4.1.1 Ultimate Strength ------------------------------------------------------------------------------------------- 26
4.1.2 Cracking Strength ------------------------------------------------------------------------------------------- 26
4.1.3 Shear and Torsion ------------------------------------------------------------------------------------------ 26
4.1.4 Deflection ----------------------------------------------------------------------------------------------------- 26
4.1.5 Prestress Losses --------------------------------------------------------------------------------------------- 26
4.2 Design Methodology ------------------------------------------------------------------------------------------- 27
4.2.1 Ultimate Moment Capacity -------------------------------------------------------------------------------- 27
4.2.2 Cracking Moment Capacity -------------------------------------------------------------------------------- 29
4.2.3 Zero-Tension Moment ------------------------------------------------------------------------------------- 30
4.2.4 Calculation of Shear Capacity ----------------------------------------------------------------------------- 31
4.2.5 Calculation of Torsion -------------------------------------------------------------------------------------- 32
CASE STUDIES --------------------------------------------------------------------------------------------------------- 33
5.1 Ceylon Electricity Board (CEB) ------------------------------------------------------------------------------ 33
5.1.1 Design Loading ---------------------------------------------------------------------------------------------- 33
5.1.2 Design Parameters ------------------------------------------------------------------------------------------ 33
5.1.3 Final results of the design for CEB ----------------------------------------------------------------------- 34
5.2 Sri Lanka Telecom (SLT) -------------------------------------------------------------------------------------- 35
5.2.1 Design loads -------------------------------------------------------------------------------------------------- 35
5.2.3 Design Parameters ------------------------------------------------------------------------------------------ 35
5.2.4 Final results of the design for SLT ----------------------------------------------------------------------- 36
COST CALCULATION ------------------------------------------------------------------------------------------------- 37
CONCLUSIONS --------------------------------------------------------------------------------------------------------- 40
Bibliography ------------------------------------------------------------------------------------------------------------------ 41
ANNEX 1- CEB Specification for Reinforced Concrete Poles --------------------------------------------------------- ix
ANNEX 2- SLT Specification for Reinforced Concrete Poles ----------------------------------------------------------- x
ANNEX 3- Design Calculations --------------------------------------------------------------------------------------------- ix
v
LIST OF FIGURES
LIST OF TABLES
Table 2-1: Comparison of Performance with Different Types of Utility Poles (Oliphant, et al., 2012) .......... 10
Table 2-2: Equipment for Prestressed Concrete Pole Production: Source- (Shijiazhuang, 2015) ................. 16
Table 5-1: Design loads on CEB poles ......................................................................................................................................... 33
Table 5-2: Design Parameters ........................................................................................................................................................ 33
Table 5-3: Dimensions of the Different CEB Poles - * Ground supported length is taken as 1/9th of pole
length ......................................................................................................................................................................................................... 34
Table 5-4: Results of the Design for CEB Poles ...................................................................................................................... 34
Table 5-5: Design loads on SLT poles .......................................................................................................................................... 35
Table 5-6: Dimensions of the Different SLT Poles - * Ground supported length is taken as 1/5th of pole
length ......................................................................................................................................................................................................... 36
Table 5-7: Results of the Design for SLT Poles ........................................................................................................................ 36
Table 6-1: Cost Calculation for production of 100 no’s of 5.6m length poles (SLT) ............................................... 38
Table 6-2: Cost comparison of Proposed Poles with Equivalent Currently Using Poles ...................................... 39
vi
LIST OF EQUATIONS
vii
LIST OF ABBREVIATION
Abbreviation Description
viii
Chapter 1
Introduction
INTRODUCTION
1.1 General
1.2 Background
Spun-casting is not a new technology for Sri Lanka since we have been
manufacturing' spun concrete pipes since about 1940 by using it (Mendis,
1980).But it happens to be obvious that we haven’t had enough technological
knowledge or an industrial inspiration to improve the range of spun cast pre-
stressed products in Sri Lanka. While we stuck with old machines and technology,
the world has moved fast with different materials and methods to produce
different spun cast pre-stressed elements. (e.g. Transmission Poles/Towers,
Street Yard lighting, Traffic signal poles, Overhead electrical traction poles for
Railway electrification, Grid Sub-stations Structures, circular precast spun piles,
etc.) Even though we have a very little researches on this sector of concrete
casting in Sri Lanka, we have enough chance to follow researches done on
different countries of the world, and design our own products.
1.3 Scope
This study includes alternative design and cost estimation of Circular Spun Cast
Pre-stressed Concrete Poles which can be used as utility poles in Sri Lanka.
1
Chapter 1
Introduction
1.4 Objectives
With the material and labour cost for production of normal reinforced concrete
is increasing continuously over the years, the both manufacturers and buyers
should find new solutions which can provide cost effective alternatives for them.
Spun-casting has proved to be such an alternative prestressed pole production
technology in most of the foreign countries. So, the main objectives of this
research is,
1.5 Methodology
The steps followed in completing this research are given in the following chart.
Detailed explanation on methodology is described in a separate chapter.
Problem Identification
and Litrerature Survey
Literature
Survey
SLT CEB
Alternative Alternative
Pole Design Pole Design
Cost
Calculation
Conclusions
2
Chapter 1
Introduction
1.6 Outcomes
Alternative spun-cast prestressed poles for Sri Lanka Telecom and Ceylon
Electricity Board were designed to comply with the specifications of each
of the companies.
The cost calculation done for the design according to the Building
Schedule Rates (BSR) 2013, proved over 20% of cost reduction is possible
with this proposed alternative poles in this study.
Because of the hollow nature of the poles, about 10% weight reduction
was achieved, with respect to the normally reinforced concrete poles.
Literature review begins with the history of spun cast concrete technology and
prestressed pole structures. Different structural configurations of poles and
advantages of spun poles over other types of utility poles like wood, steel and
normal reinforced concrete is discussed in this chapter with reference to the
available literature. Then standard and specifications for the materials which are
recommended by selected literature is described. A brief description about
steam curing and typical machinery & equipment in a spun-cast prestressed pole
manufacturing factory is mentioned. Finally some findings from previous studies
done in Sri Lanka on spun-casting are discussed.
Next chapter is about research methodology. The steps which were followed in
completion of this research is mentioned by step by step with some details.
“Design of pre-stressed spun cast poles” gives the detail design procedure which
was followed including the formulas used for the design of poles mentioned in
the design case-study.
Two case-studies were done and according to the specific loading and testing
requirements of those case-studies, alternative spun-cast prestressed poles were
designed. In the next chapter the results of the design for these case-studies are
mentioned.
Cost Calculation for the poles according to the BSR-2013 and current market
price of materials is given in the next chapter. Also a comparison of cost with the
equivalent normal reinforced concrete poles is also done in that chapter.
3
Chapter 1
Introduction
The conclusions chapter summarizes all the work done and in the research,
results and outcomes and future work need to be done in this area, to extracts
more benefits from spun-cast technology.
4
Chapter 2
Literature Review
LITERATURE REVIEW
2.1 General
Concrete poles have been used since the invention of reinforced concrete.
According to the article named “Spun Prestressed Concrete Poles – Past, Present,
and Future”, the first concrete poles had used in Germany in 1856 for supporting
telegraph lines. (Fouad, et al., 1992) Joseph Monier of France had produced the
first iron-reinforced concrete poles in 1867.The concrete poles had increased
strength and durability but usage was limited due to the heavier weight when
compared to wood and steel.
In 1930, Eugene Freyssinet developed the first prestressed concrete poles. They
could withstand higher loads without cracking and could exhibited elastic
characteristics. (Thomas E. Rodgers, 1984) When the World War 2 stuck the
world, a shortage of steel had boosted the production of prestressed poles
because they require less R/F steel. (Fouad, et al., 1992)
Pre-stressed concrete poles are lighter but stronger, and they require less
reinforcing steel. The concrete is generally in compression, so cracking is unlikely
except from rough handling, and the concrete used is of higher strength so it can
withstand the pre-stressing operation. Due to the special manufacturing process,
in which the poles are spun at high speeds, they have a smoother surface that is
denser and less permeable. This lower permeability in combination with the
absence of cracks prevents corrosion of reinforcement or pre-stressing wires.
The pre-stressed concrete can be made stronger and slender. (Ahmed &
Munudhada, 2013)
The two types of pre-stressed concrete poles predominantly used in the electrical
utility industry are centrifugally cast (commonly referred to as spun cast) and
5
Chapter 2
Literature Review
statically cast. Spun poles have a round or a polygonal cross section with a hollow
core that is created by the spinning process. The size of the hollow core depends
on the pole diameter and wall thickness. Statically cast poles have a square or
polygonal cross section with a core that is solid or a hollow core formed by a
retractable mandrel or a permanent form. Although both centrifugally cast and
statically cast poles are referred to as pre-stressed concrete poles, each has
differences in performance, specification, and recommended use. (Oliphant, et al.,
2012)
Pre-stressed concrete poles are primarily used in one of the following four
structural configurations:
Cantilevered
Guyed
Framed
Combined (Concrete pole substation structures)
6
Chapter 2
Literature Review
The first spun cast concrete poles were first produced in 1907, by a German firm
Otto Schlosser in Meissen, northwest of Dresden. A wide range of spun concrete
poles are produced, ranging from 6 m long, 200 mm base diameter poles to 100
m long, 2 m base diameter poles. These poles are used for flag poles, sign poles,
telephone/telegraph poles, street lighting and electric power line poles, overhead
power lines for electrical trains, etc. Sometimes several pole sections are joined
together to produce poles over 100 m long, post-tensioned and used as towers
for communication equipment. (Thomas E. Rodgers, 1984)
Firms are trying to find new application fields and reduce the cost of production,
transportation and installation. Today even more spun-cast reinforced concrete
columns are installed into high-rise buildings and other structures. (Völgyi, et al.,
2010)
Spun concrete piles are another product which has obtain the attention of the
precast industry in recent years. They can be produced in a hollow, circular cross
section of high density R/F of pre-stressed concrete. Their efficient mass-to
strength weight ratio allows longer lengths which eliminate the need of joints.
Accurate dimensions and smooth dense finish of the surface are also helpful. The
skin friction of the piles also increases due to the two surfaces created by the
hollow cross section and so the bearing capacity of the pile just increases than
similar sizes of square piles. (Anon., 2005)
Circular hollow cross-sections are always better for longer poles. As they’re
hollow, they weigh less. And because they’re circular, strength is equal in all
directions. They are spun at high speeds in the casting operation, the concrete is
denser and stronger. Cylindrical poles can be made, but most spun-cast poles
have a uniform taper from top to bottom. The taper usually ranges from 0.15 to
0.18 inch per foot. ( (Thomas E. Rodgers, 1984)
7
Chapter 2
Literature Review
There are three types of poles used for utility work in Sri Lanka. They are
normally reinforced concrete poles, steel poles and wooden poles. Therefore, to
justify the use of prestressed spun concrete poles over those poles, we have to
look into the advantages of spun poles. If we list them down,
8
Chapter 2
Literature Review
The following table shows a generalized and qualitative comparison of Spun Cast
Concrete poles with common alternatives. Here “Favorable” represents the better
performance with respect to the considered parameter while “average” and
“poor” carries the usual meanings of those words. The comparison has been made
for typical direct embedded, tangent structures with a fixed right-of-way width.
The ratings are based on the experience of the committee members of
“Prestressed Concrete Transmission Pole Structures- Recommended Practice for
Design and Installation”.
9
Chapter 2
Literature Review
Environmental
Favorable Poor Favorable Favorable
Impact
Salt water/
corrosive Favorable Poor Poor Average
Environment
Strength
Average Poor Favorable Poor
Capacity
Ease of
Average Favorable Average Average
Replacement
Disposal/Recycle
Average Poor Favorable Average
at Replacement
Short duration
Favorable Poor Average Poor
fire resistance
The two main materials in the pre-stressed concrete poles are concrete and steel
reinforcement. Here, the guidelines and specifications of those materials are
discussed.
10
Chapter 2
Literature Review
Selecting specific quality materials for the spun cast poles is very important to
ensure the safety, durability and quality of the pole structure. Grade 50 concrete
is selected for this particular design but high strength concrete from 50-100
N/mm2 is used for pole production. ((NRECA)., 2009)
Cement
o Portland Cement shall be either Type I, II, III, or V Portland cement
conforming to ASTM C150 (ASTM 2011c)
Fine Aggregate (Sand)
o Fine aggregate shall be a natural sand, consisting of clean, strong,
hard, durable uncoated which conforms to ASTM C33 (ASTM
2011b). Fine aggregate should be free from clay, silt, salt or other
impurities that are harmful and initiate early deterioration of the
structure.
o The aggregate shall be well graded from No. 4 to No. 200 sieve.
o Sea sand is not suitable due to salt nature
Course Aggregate
o Coarse aggregate shall be clean, tough, crushed stone conforming
to ASTM C33
o Maximum size aggregate should be 3/4 in., and not exceed three-
fourths of the clear spacing between reinforcing steel and pole
surface. In the designs done during this research, coarse aggregate
with maximum size of 14mm aggregates were used.
o Resistance to abrasion shall not exceed 40% as tested in
conformance with ASTM C131.
o Absorption shall be less than 4 percent or aggregate shall be
saturated with water prior to use in concrete
o AIV is less than 20% for crushed aggregates
Water
o Water should be free from foreign materials in amounts harmful to
concrete and embedded steel.
o It should not contain concentration of chloride ions excess of 500 ppm
and sulphate ions in excess of 1000 ppm.
Admixtures
o Water reducing, retarding, and accelerating admixtures should
conform to ASTM C494 (ASTM 2011a).
o Admixtures should not contain chloride ions in quantities that
would cause the total chloride content of the concrete to exceed 0.4
pound per cubic yard.
11
Chapter 2
Literature Review
Poles are prestressed with either uncoated, stress relieved steel wire (ASTM
[2010c], grade 250 or 270) or uncoated low relaxation and stress relieved seven-
wire strand (ASTM [2010b], grade 250 or 270).
In designs done in here, prestressing stands with 0.2% yield strength over
1600N/mm2 and Tensile Strength of over 1750 N/mm2 is used which has 3,5%
of minimum elongation at maximum load.
The spiral reinforcement generally conforms to ASTM A82 (ASTM 2007). Its size
should be in the range of No.5 to No. 11 gauge wire, depending on the pole use
and size. To resist the radial stresses that occur at transfer of prestress, more
12
Chapter 2
Literature Review
spiral reinforcement is required at the tip and butt segments of the pole. Other
areas of high shear stress, such as guy wire or other attachments and near the
ground line, may need additional spiral reinforcement.
Therefor the selected Spiral shear reinforcement will be 2.5mm diameter mild
steel wires with 250 N/mm2, 14% of minimum elongation at maximum load and
tensile strength of 350 N/mm2. Centre to centre spacing between successive
spirals are decreased at top and bottom and minimum is provided in the middle.
13
Chapter 2
Literature Review
In spinning process of the poles, concrete mixes can undergo serious segregation
problems and the dry or coarse mixes would not consolidate properly. Therefor
Dilger, Ghali and Rao (1996), Dilger and Rao (1997), and Wang, Dilger, and
Kuebler (2001) determined that special mix designs were required for spun cast
concrete poles. For this drying shrinkage, freeze thaw, chloride penetration, mix
proportions and mixing time, spinning speeds and duration were all investigated.
Differential shrinkage between the inner and outer layers was linked to the
longitudinal cracking of concrete poles causing deterioration, reduction in
strength, and reduced life expectancy. Longitudinal cracking is also identified as
a typical problem. (Kuebler, 2008)
The minimum design 28-day concrete cylinder compressive strength f'c is 5,000
psi. Generally 6,000 to 12,000 psi strength are being used. ASTM C39 (ASTM
2004) is used to determine the compressive strength of concrete. (Oliphant, et al.,
2012)
Steam curing is a method in which elevated curing temperatures and the addition
of moisture during the curing process are both used in order to accelerate the
14
Chapter 2
Literature Review
rate of strength gain. The basic method of steam curing at atmospheric pressure,
for the most part, follows the same stages present in any accelerated curing
process involving elevated curing temperatures. (Vollenweider, 2004)
60
50
Temperature C
40
30
20
10
0
1 2 3 4 5 6 7 8 9 10 11 12
Time (Hours)
15
Chapter 2
Literature Review
Measuring and
Concrete PL800:48m 3/h (capacity is dependent
batching raw
Batching on concrete pole specifications and
concrete
Plant production capacity)
materials
Power of motor:22KW
Spinning Driving mould to
Distance between shafts:800mm
Machine spin
Spinning speed:60-600rpm
Power:380v
Power consumption:5.5KW
Heading
Heading Heading HT wire
diameter:7.1mm,9mm,10.7mm,12.6mm
Machine or PC steel bar
Speed of heading:4-6 head/min
Max strength of clamp:50T
Max of upsetting force:16T
Tension of HT
Tension Dependent on prestressing steel tensile
wire or PC steel
Machine force
bar
Automatic
Cutting bar into
bar cutting Depends on steel length and diameter
given length
machine
16
Chapter 2
Literature Review
Temperature: 151ºC
Steam capacity is dependent on
production capacity
To lift up and
move mould and Load:20T Span:30M Height 4M(Standard
Bridge Crane
finished configuration)
products
To lift up and
move finished Load:10T Span:30M Height 6M(Standard
Gantry Crane
products to configuration)
storage place
Automatic
To feed concrete Feeding speed is dependent on
Feeding
into moulds production capacity.
Machine
Figure 2-4: Automatic concrete mixture (left) and spinning machine (right)
17
Chapter 2
Literature Review
18
Chapter 2
Literature Review
19
Chapter 2
Literature Review
The main design loads on poles are typically due to wind on the pole, arms, and
fixtures. These loads primarily produce bending moments, but also shear forces,
and torsional moments. Kuebler has presented some of these failures in his
research “Torsion in Helically Reinforced Prestressed Concrete Poles” and two of
the major failures are briefly mentioned here.
Vehicle Impact
o Normally the result of a vehicle impacts is the shear failure of
concrete poles between the bumper level and the ground. A typical
shear failure caused by vehicle impact is shown in the following
figure. The crack caused by vehicle impact originates at the
bumper level and proceeds diagonally towards the ground level.
o The use of tight spirals can minimize the damaged area of the pole,
while longitudinal reinforcement can provide the pole stability in
the case of complete concrete section loss.
20
Chapter 2
Literature Review
Apparently, studies on spun cast pre-stressed poles had never been conducted in
Sri Lanka at a broader scale. And even though some researches may were done,
they haven’t been published to get the attention of public. The only detailed study
I could find had done by Mr D.L.O. Mendis, and there we can find some interesting
facts about the history of the use of this technology in Sri Lanka.
The first use of spun concrete technology in Sri Lanka appears to have been by
the Indian Hume Pipe Company, which has been manufacturing' spun concrete
pipes since about 1940 using imported process technology. The River Valleys
Development Board, the State Development and Construction Corporation and
the State Engineering Corp., have also established spun concrete plants within the
last 20 years or so. (In 1960s) (Mendis, 1980)
21
Chapter 2
Literature Review
In this paper Mr Mendis suggest to use this technology for manufacturing of half
round cylindrical lining for the irrigation channels, conduit pipes without any
reinforcement which are used to carry underground cables and also hollow
tapered concrete poles in Sri Lanka.
Perhaps the most elegant product of spun-concrete technology that has been
developed locally is the hollow tapered concrete pole. This product has many
applications including light transmission poles for electricity and
telecommunication as well as light poles, as an alternative to the solid rectangular
R. C. C. poles and the pre-stressed concrete poles which are used at present. Heavy
transmission line poles as an alternative to fabricated steel pylons and towers,
various special uses such as flood lighting poles, chimneys or exhaust pipes, etc.
are also possible. A hollow concrete pile may also be developed in the future. All
these products are in commercial production by patent process abroad. (Mendis,
1980)
22
Chapter 3
Research Methodology
RESEARCH METHODOLOGY
Even though it can be highlighted that the Spun Cast pre-stressed poles have lot
of advantages over conventional pole production technologies, the knowledge
about this technology and its applications are very rare in Sri Lanka. So, it is
beneficiary for both country and the industry to have a new view or a discussion
about spun casting and its potential applications. This research will not be a
guideline for future spun pole design/production but it can be an example or a
light for the development of the technology in the country.
It is always easy to continue something with the experience of the past, rather
than starting something fresh or all new. Actually the world has moved fast
forward with this technology while we were stuck with it for the production of
cylinders. Many researches had been doing this area with different case studies
and applications, different materials, curing technologies, Modal Behaviours of
concrete elements by different academics and professionals around the world.
23
Chapter 3
Research Methodology
One of the major benefits of Spun Cast Pre-stressed poles is the reduced cost in
terms of manufacturing and lifecycle. So a small cost calculation was done to
prove the design id feasible and cost effective to proceed with the manufacturing
as it is. Programs for cost estimation were developed & linked with the main
program. Rates were taken from BSR 2013, current market price of materials and
considering wagers of workers in these days.
However the limitation of this calculation was applying overhead costs for
machinery, factory insurance, transportation and other taxes for local
governments, since they are relative to the location and size of the factory.
Therefor 50% of cost for labour plus material was taken as the total overhead
cost for the pole production including staff, electricity, fuel and depreciation
costs.
3.5 Conclusion
At the end of the research, a conclusion of results and recommendations for the
manufacturing of poles will be presented.
24
Chapter 4
Design of Prestressed Spun Cast Poles
When bending forces applied to the cross section, the section properties of a
prestressed concrete pole get changed. This cause tensile forces on the face of the
pole to exceed the compressive forces exerted by the prestressed steel. The
bending moment at which this occurs is called the cracking moment. Prior to
reaching the cracking moment, the pole section has a relatively constant modulus
of elasticity and deflects in a linear manner. After the cracking moment is passed,
the pole section behaves mostly nonlinearly because of the altered properties of
the cracked section. Actually both behaviours can be present at the same time
during loading. For an example the top half of the pole may not yet have exceeded
the cracking moment and thus behaves linearly, while the bottom half of the pole
has exceeded the cracking moment and thus behaves nonlinear manner.
The design of this type of poles can be separated into two parts.
25
Chapter 4
Design of Prestressed Spun Cast Poles
So in this research the main focus is put into the design of Outer Shaft of the Spun-
cast prestressed poles.
The ultimate flexural strength of a pole is the point at which the pole will fail.
Normally it happens by compressive failure of the concrete. Therefore the pole
should be designed for the ultimate strength at all sections of the pole to exceed
the required strength calculated from the appropriate factored loads applied to
the structure. Factored loads are generally specified by the purchaser or
applicable codes are used (e.g. ASCE 2010).
Shear and torsion are not that important in concrete pole designs. But if the
concrete pole has very short embedment, the concentrated shear forces from the
moment transfer can be significant and should be accounted for in the pole
design. High shear and torsion loads can be developed from conductor or guy
wire attachments or under broken wire conditions at operation stage.
4.1.4 Deflection
The Purchaser should specify the deflection limit and the associated load cases to
be considered in the pole design.
The magnitude of the prestressing force in the pole is not constant but decreases
with time. This phenomenon is referred to as the prestress loss. Two kinds of
prestress losses-instantaneous and time-dependent. Instantaneous losses are
due to elastic shortening, anchorage slippage, and friction in the case of post-
tensioning. Time-dependent losses are mainly due to shrinkage and creep of
concrete and relaxation of steel. Detailed analysis of losses for prestressed
26
Chapter 4
Design of Prestressed Spun Cast Poles
concrete poles may not be necessary except in unusual circumstances. Lump sum
estimates of losses are commonly used. Depending on the materials used, 15 -
20% for total losses are common design assumptions. A good source for
information on the calculation of prestressing losses is PCI (2010). Here, a lump
sum pre-stress loss on pole is taken as 15%and the tendons are allowed to be pre-
stressed up to 90% of the yield strength.
A prestressed pole at any given cross section is a function of the strains in the pre-
stressing steel and concrete. The factored design moment should not exceed the
ultimate moment capacity.
Assumptions made,
27
Chapter 4
Design of Prestressed Spun Cast Poles
Figure 4-1: Concrete stress area and assumed stress distribution in the pole section
4.2.1.2 Calculate the Compression in Concrete
Cc = Concrete in compression
28
Chapter 4
Design of Prestressed Spun Cast Poles
For the equilibrium of the section, equal forces in the pre-stressing steel and
concrete is required.
The ultimate moment capacity of a pole section is given as the sum of the
moments of tensile and compressive forces with respect to the neutral axis.
Here Φ is the capacity reduction factor and it is taken as 0.9 in the calculations.
Cracking starts when the tensile stress in the extreme fibre of the concrete
reaches its modulus of rupture. The cracking moment can be computed by elastic
theory to predict the behaviour of poles.
29
Chapter 4
Design of Prestressed Spun Cast Poles
ACI 318 (ACI 2008) defines the modulus of rupture for normal weight concrete
as 7.5√𝑓′𝑐. However, ACI recognizes a transition zone where the extreme
concrete fibre tensile stress ranges from 7.5√𝑓′𝑐 to 12√𝑓′𝑐. Currently, values of
up to 10√𝑓′𝑐 are used by Manufacturers based on individual testing.
30
Chapter 4
Design of Prestressed Spun Cast Poles
The Shear capacity of the concrete poles may calculated using following
equations.
31
Chapter 4
Design of Prestressed Spun Cast Poles
The design of concrete pole cross sections subjected to torsion shall be based on,
32
Chapter 5
Case Studies
CASE STUDIES
In Sri Lanka, we do not have big variety of customers who consume large
quantities of poles yearly. The main customers are SLT and CEB where both are
government bodies. SLT normally consume over 100,000 poles yearly, and so it
can be predicted that the CEB pole consumption is way too high. Municipal
councils or local governments does consume a significant amount of street
lighting. Therefor some alternative spun-cast prestressed poles were designed
here, to comply with the acceptable criteria of SLT and CEB.
33
Chapter 5
Case Studies
Table 5-3: Dimensions of the Different CEB Poles - * Ground supported length is
taken as 1/9th of pole length
6m 8.3m 9m 10m
Size of Strands(mm) 4.8 6 6 10
No of Strands 6 6 6 8
Pre-stressing force needs to be 156.4 244.2 244.4 435.6
applied (kN)
Pre-stressing force after allow 132.9 207.6 207.7 370.3
for 15% losses (kN)
Ultimate Moment Capacity 11.56 25.34 27.79 61.32
(kNm) (>5.8) (>16.62) (>20.87) (>60.98)
Cracking Moment (kNm) 12.77 24.09 27.79 42.58
Zero Tension Moment (kNm) 5.89 12.14 13.38 25.19
34
Chapter 5
Case Studies
Design loads of SLT poles were collected from a tender document published by
SLT and is attached to the APPENDIX 2 in this report. There they have specified
the breaking load on each pole also, which is considered in the testing and
acceptance criteria of SLT published on the same document.
Design parameters for SLT poles does not change significantly from Table 5-2
except fixing length/total pole height of the pole be 1/5 and load application
height be 0.5m. Refer APPENDIX 3 for design calcuations.
35
Chapter 5
Case Studies
Table 5-6: Dimensions of the Different SLT Poles - * Ground supported length is
taken as 1/5th of pole length
No of Strands 6 6 6 6
36
Chapter 6
Cost Calculation
COST CALCULATION
The basic cost calculation for the proposed design of poles was done with
reference to the BSR-2013: Reference for BOQ, current market price of materials
and assumed electricity and depreciation costs of the factory.
Assumptions
The manufacturing capacity of the factory is 100 poles per day (This will
be a minimum value considering the capacity of a typical factory.)
50% of total material and labour costs were taken as the overhead.
The main reason for this 50% margin of overhead is the difficulties in calculation
of more realistic values for machinery, factory insurance, transportation costs
and other taxes for local governments, since they are relative to the location and
size of the factory.
According to the table 6-1, the production cost per single 6m Spun-cast
prestressed pole would be around Rs 4,321.00. And the competitor normally
reinforced concrete pole would be around Rs.5900.00. So the cost saving would
be about 23%.
Then the same cost calculation was done for all designed poles and the results
were compared with the current market price of the equivalent normally
reinforced concrete poles. It is presented in table 6-2.
37
Chapter 6
Cost Calculation
Table 6-1: Cost Calculation for production of 100 no’s of 5.6m length poles (SLT)
38
Chapter 6
Cost Calculation
Table 6-2: Cost comparison of Proposed Poles with Equivalent Currently Using Poles
Pole Cost
Cost
size Normal R/F Spun Cast
Reduction
(m) Concrete poles Prestressed Poles
5.6 Rs 5,500.00 Rs 4313.93 21.4%
6.7 Rs 7,800.00 Rs 6,050.33 22.4%
SLT
7.2 Rs 11,500.00 Rs 6,448.44 43.9%
8 Rs 11,900.00 Rs 7,081.97 40.5%
6 Rs 5,600.00 Rs 4,321.67 22.8%
8.3 Rs 12,000.00 Rs 7,575.41 36.9%
CEB
9 Rs 12,500.00 Rs 8,466.35 32.3%
10 Rs 21,000.00 Rs 15,823.17 24.7%
39
Chapter 7
Conclusions
CONCLUSIONS
40
Bibliography
Bibliography
Fouad, F., Sherman, D., & Werner, R. (1992). Spun Prestressed Concrete Poles –
Past, Present, and Future. Concrete International, 14(11), 25-29.
Heritage, I., Khalaf, F., & Wilson, J. (2000). Thermal Acceleration of Portland
Cement Concretes Using Direct Electronic Curing. ACI Materials Journal,
January-February, 37-40.
Oliphant, W., Sherman, D., Agnew, F., Bragdon, M., Chandler,, B., Crissey, D., . . .
Wong, C. (2012). Prestressed Concrete Transmission Pole Structures-
Recommended Practice for Oesign and Installation. Virginia: ASCE
American Society Of Civil Engineers.
41
Bibliography
Völgyi, I., Farkas, G., & Nehme, S. (2010, 01 03). Concrete strength tendency in the
wall of cylindrical spun-cast concrete elements. Periodica polytechnica, pp.
23-30.
42
ANNEX 1- CEB Specifications for Reinforced Concrete
Poles
ix
ANNEX 1- CEB Specifications for Reinforced Concrete
x
ANNEX 1- CEB Specifications for Reinforced Concrete
xi
ANNEX 1- CEB Specifications for Reinforced Concrete
xii
ANNEX 1- CEB Specifications for Reinforced Concrete
xiii
ANNEX 1- CEB Specifications for Reinforced Concrete
xiv
ANNEX 1- CEB Specifications for Reinforced Concrete
xv
ANNEX 1- CEB Specifications for Reinforced Concrete
xvi
ANNEX 1- CEB Specifications for Reinforced Concrete
xvii
ANNEX 1- CEB Specifications for Reinforced Concrete
xviii
ANNEX 1- CEB Specifications for Reinforced Concrete
xix
ANNEX 1- CEB Specifications for Reinforced Concrete
xx
ANNEX 1- CEB Specifications for Reinforced Concrete
xxi
ANNEX 1- CEB Specifications for Reinforced Concrete
xxii
ANNEX 1- CEB Specifications for Reinforced Concrete
xxiii
ANNEX 1- CEB Specifications for Reinforced Concrete
xxiv
ANNEX 1- CEB Specifications for Reinforced Concrete
xxv
ANNEX 1- CEB Specifications for Reinforced Concrete
xxvi
ANNEX 1- CEB Specifications for Reinforced Concrete
xxvii
ANNEX 1- CEB Specifications for Reinforced Concrete
xxviii
ANNEX 2- SLT Specifications for Reinforced Concrete
x
ANNEX 2- SLT Specifications for Reinforced Concrete
xi
ANNEX 2- SLT Specifications for Reinforced Concrete
xii
ANNEX 2- SLT Specifications for Reinforced Concrete
xiii
ANNEX 2- SLT Specifications for Reinforced Concrete
xiv
ANNEX 3- Design Calculations
β1 = 0.85- [(5801.509756-4000)*0.05/1000] ;
f’c>4000psi
=0.76 >0.65 hence ok
β1=0.76
Strain of concrete in compression : ϵcu (in)= 0.003
Height above the testing level= 6*(8/9)= 5.33m
ix
ANNEX 3- Design Calculations
x
ANNEX 3- Design Calculations
Sin θ1=2sin(θ/2)cos(θ/2)
√(𝑟1)2 − (𝑟1 − 𝛽𝑐)2 ⁄ (𝑟1 − 𝛽𝑐)⁄
=2* ( 𝑟1 )* ( 𝑟1)
(2 ∗ (𝑟1 − 𝛽𝑐) ∗ √(𝑟1)2 − (𝑟1 − 𝛽𝑐)2 )⁄
= (𝑟1)2
(2 ∗ (114 − 50) ∗ √(114)2 − (114 − 50)2 )⁄
= (114)2
=0.92917
Area of bigger annulus=
A1= [2*cos-1((114 − 50 ⁄114 ))- 0.92917)]* 1142/2
= 6629.66mm2
(2 ∗ (114 − 50) ∗ √(68.5)2 − (114 − 50)2 )⁄
Sinθ2= (68.5)2
= 0.131
Area of smaller annulus=
114 − 50) ⁄
A2= [2*cos-1(( 68.5 )- 0.131]* 68.5 /2
2
= 157.75 mm2
Therefore,
Area of concrete in compression= 6629.66-157.75
Aa = 6472.28 mm2 Aa = 6472.28
mm2
xi
ANNEX 3- Design Calculations
Then,
Radius of circle trough pre-stressing wires Rw= R1- (cover of
R/F+ Dia. spiral R/F+ Dia. Strands/2) =90.1mm
xii
ANNEX 3- Design Calculations
xiii
ANNEX 3- Design Calculations
xiv
ANNEX 3- Design Calculations
Similarly,
By assuming 8 wire configuration we can get a ultimate
moment capacity of 16.19 kNm and assuming 4 wire
configuration we can get a ultimate moment capacity of 8.02
kNm
4 wire configuration is rejected considering the experience
because the spacing between strands (in cross section) is too
much.
8 wire configuration is rejected because it makes the section
over reinforced.
= 10 × √5801.51 *.00689
xv
ANNEX 3- Design Calculations
=5.25
Gross Area = Ag= 3.141592*(1142-68.52)
= 26087 mm2
Ig = 115358320.4 mm4
Maximum prestress force applied =P= 132889.68 N
𝑓𝑟 ∗ 𝐼𝑔⁄ 𝑃 ∗ 𝐼𝑔
Cracking moment= Mcr =( 𝑦𝑡) + ( ⁄𝐴𝑔 ∗ 𝑦𝑡)
=(5.25 ∗ 115358320.4⁄114) +
𝑃 ∗ 𝐼𝑔
M0= ⁄𝐴𝑔 ∗ 𝑦𝑡
Shear Capacity
f1t= 4*√5801.51 *0.00689
= 2.099 kN
fpc= 132910.42/26087
= 5.095 kN
(1143 − 68.53 )
Q = (4⁄(3 ∗ 3.141592 ∗)) ∗ ( ⁄ 2
114 − 68.52 )) ∗
(26087⁄2)
= 773416.7
xvi
ANNEX 3- Design Calculations
2
=√2.099 + 2.099 ∗ 5.095⁄ 773416.7∗1000
(2∗115358320.4∗(114−68.5))
=52.54 kN Vc =52.54 kN
𝐴𝑣 ∗ 𝑓𝑦 ∗ 𝑑⁄
Nominal shear strength by shear R/F= Vs= 𝑠
=
4.9 ∗ 250 ∗ 114 ∗ 2⁄
100
Vs= 2.79 kN
= 2.79 kN
Shear Capacity = (52.54 + 2.79 )*0.75
V= 41.08 kN
= 41.08 kN
xvii