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Prestressed Concrete Poles:

State-of-the-Art

Thomas E. Rodgers, Jr.


Director Structural Engineering
VEPCO, Virginia Electric and
Power Company
Richmond, Virginia

F or many years throughout the world,


poles made of wood, steel, and con-
crete have been used to support power
years ago, conducted his classic dem-
onstration in which a normal reinforced
concrete pole and a prestressed pole,
transmission, telephone and telegraph designed to the same ultimate load,
lines, street lighting, overhead power were placed in a special testing ap-
lines for railroads, and antenna masts, paratus and subjected, not only to rep-
Concrete poles were first used over 60 etition of a load equal to, but also to al-
years ago and were then made of normal ternation of a load amounting to 50 per-
reinforced concrete. As technology im- cent of the designed ultimate load. The
proved, production and use of concrete normal reinforced concrete pole failed
poles gradually increased. at a few thousand repetitions, but the
Prestressed concrete poles should not prestressed pole was still going strong at
be regarded as novel or new. They were 500,000 cycles. Since this is the type of
first designed and constructed by the loading that poles are expected to carry
French prestressing pioneer Eugene in the field, this test was of significant
Freyssinet in Algeria in the middle interest to pole users.
1930s. The greatest hazard associated with
It was also Freyssinet who, many normal reinforced concrete poles is cor-
rosion of steel, This leads to spalling of
NOTE: This state-of-the-an report forms part of
the concrete and, ultimately, failure of
the work of the PCI Committee on Prestressed the pole. The corrosion may be caused
Concrete Poles, of which the author is a by insufficient cover, substandard con-
member and former chairman. The document crete, or excessive tensile forces, hence
has been reviewed and endorsed by the Poles cracks, in handling or service, owing to
Committee and the Technical Activities Com- poor design or to misuse. Any of these
mittee for publication and discussion. conditions can cause penetration of

52
water to the steel. The process might
take several years, but once corrosion is Synopsis
started, failure becomes inevitable.
The prestressed concrete pole offers Presents an historical and state-
the following advantages: First; the con- of-the-art review of the application,
crete used is of a quality sufficient to design, manufacture, testing, han-
resist penetration of water, otherwise dling, transportation, and erection of
the pole could conceivably fail during prestressed concrete poles through-
the prestressing operation. Secondly, in out the world. Particular emphasis is
a prestressed pole, the concrete is usu- given to centrifugally spun precast
ally in compression, and cracking is not concrete poles.
possible except under abnormal condi- Design criteria (especially load
tions of handling or service. These selection) are discussed in detail to-
characteristics give the prestressed pole gether with the relevant provisions
greater advantages over the normal from the various codes of practice. It is
reinforced pole and are the reasons for concluded that prestressed concrete
the development and use of prestressed poles will play an increasingly domi-
concrete poles. nant role in the future.
Today, prestressed concrete poles are
widely used throughout Eastern and
Western Europe. They are extensively
utilized in Japan and to varying degrees
in many other countries around the pole plant belonging to the Shanghai
world. Available data indicate that the Electricity Bureau in China, which
Soviet Union has produced and used the started spinning regular reinforced con-
most poles, whereas the United States crete poles in 1958 and prestressed
and Canada have only recently initiated poles in 1968 (Figs. 1 and 2).
their utilization. In East Germany prestressed concrete
poles find application in many fields. In
the following industries, of the total
SCOPE OF number of poles, the percentages for
APPLICATION prestressed concrete are: for electric
power transmission lines, 60 percent;
Prestressed concrete poles have found for overhead wires on railways, 30 per-
increasingly wide acceptance due to cent; for lighting systems, 70 percent;
their viability as a factory produced unit. and for other uses, 20 percent.
It is reported that East and West Ger- In Norway not many prestressed poles
many, Poland, and Czechoslovakia each have been produced for electric power
manufacture 50,000 to 100,000 poles a transmission because the terrain makes
year. In the Soviet Union the annual their transportation too difficult and ex-
production amounts to several hundred pensive. However, the use of pre-
thousand concrete poles. France report- stressed poles facilitated the electrifica-
edly uses more than 400,000 concrete tion of railroads in mountainous areas.
poles every year from its 14 factories In Poland and other Eastern Euro-
producing this unit. In Japan, Nippon pean countries various types of pre-
Concrete Industries, the leading man- stressed concrete poles are used for
ufacturer of spun concrete poles, pro- telephone and electric power transmis-
duces more than 5400 tons (4900 t) of sion lines.
prestressed concrete poles a month in In Western Europe spun prestressed
their eight factories, In 1979 a group of concrete poles are widely used for elec-
American engineers visited a concrete tric power transmission, railroads,

PCI JOURNAL/September-October 1984 53


Fig. 1. Spun concrete poles (Shanghai Electricity Bureau).

lighting masts and antennas, and com-


munication masts. The British Railways
have extensively used prestressed poles
for carrying overhead transmission.
Figs. 3-10 show these applications.
In the Soviet Union reinforced con-
crete poles were first used for electric
power transmission lines in 1933. Dur-
ing World War II, reinforced concrete
poles began to be used more widely.
Many poles were needed on the electric
grid as replacements for those destroyed
and for expanding the system. The
growth of the precast concrete industry
facilitated the manufacture of these
poles in various types and sizes.
The electrification of the railroad
system is of great importance to the
Soviet Union. Every year about 1250
miles (2000 km) of track are electrified,
and the use of prestressed concrete
poles to carry the overhead cables have
been a major feature of the work. The
Fig. 2. Closeup of spun concrete pole production of concrete poles for over-
(Shanghai Electricity Bureau). head cables on railroads reached

54
•E

Fig. 3. Railroad electrification structures (Western Europe).

Fig. 4. Electric power distribution structure Fig. 5. Electric power distribution structure
(Western Europe). (Western Europe).

PCI JOURNAL/September-October 1984 55


Fig. 6. Electric power transmission Fig. 7. High rise lighting structure (Western
structure (Western Europe). Europe).

Fig. 8. Street lighting structure (Western Fig. 9. Street lighting structure (Western
Europe). Europe).

56
106,000 units a year in 1959, including
some 39,000 prestressed units. Since
then, in order to use less steel but still
increase the quality of the poles, the
production of prestressed poles has
gone up and by 1964 they displaced or-
dinary reinforced concrete poles com-
pletely. The annual production of poles
for automatic signaling, telephone sys-
tems, and overhead electric power
transmission for railroads is over
100,000 units.
In Japan there is a nationwide use of
prestressed concrete poles for electric
power transmission, distribution and
substations, overhead power transmis-
sion for railroads, telephone and com-
munication systems, lighting standards,
flood-lighting, and wire netting sup-
ports. In recent years Japan has become
an exporter of large quantities of poles to
all of southeast Asia, in addition to the
west coast of North America (Fig_ s.
11-14).
Prestressed concrete poles have a!-
so been made and used for power dis-
tribution in New Zealand, Australia,
India, and South Africa since the mid
1950s.
In the United States reinforced con-
crete poles were used by some electric
utilities in the 1930s, but the first pre-
stressed concrete poles were used by Fig. 10. Communication structure
Florida Power Corporation in 1954 (Western Europe).
when they designed a 66 kV pole and an
H-section to use in a 110 kV H-frame
structure. By the early sixties, Florida pole as an aesthetic challenge. They
Power Corporation and Florida Power have continued to use the I-shaped pre-
and Light Company were using pre- stressed pole as a single circuit pole, and
stressed poles for lighting and power as a single and double circuit H-frame
distribution. Today, the Florida utilities transmission structure (Fig. 16).
are still using statically cast square pre- In 1964, the Virginia Electric and
stressed poles for lighting, distribution, Power Company (Vepco) built its first
and for some transmission up to 230 kV prestressed concrete pole structures, a
(Fig. 15). tapered I-shaped pole (Fig. 17). These
In 1962, the Eugene Water and Elec- poles were used to rebuild and upgrade,
tric Board of Eugene, Oregon, con- from 34.5 to 115 kV, a 3-mile (4.8 km)
structed I mile (1.6 km) of double- water crossing in the coastal area of
circuit H-frame 115 kV transmission line North Carolina. Each pole was set in a
along the McKenzie River, using a ta- post-tensioned, centrifugally-spun con-
pered I-shaped prestressed concrete crete cylinder pile of predetermined

PCI JOURNAUSeptember-October 1984 57


1-ig. 11. Railroad electrification structures (Japan).

Fig. 12. Electric power distribution structures (Japan).

58
length. The piles were jetted and driven
into the bottom of the Currituck Sound.
Vepco in 1966, used a static cast, tapered
square pole for lighting distribution and
some 115 kV transmission.
In 1968 Vepco changed from
statically cast poles to centrifugally-
spun prestressed poles having ta-
pered, hollow, circular cross sec-
tions. This type of pole is still being
used for lighting, distribution, transmis-
sion, and substation structures.
Currently, there are several utilities in
the United States and Canada using a
number of different types and shapes of
prestressed concrete poles for lighting
and for power transmission and dis-
tribution.

Fig. 13. Power transmission structures


(built in Japan).

Fig. 14. Telephone line structures (Japan).

PCI JOURNAL/September-October 1984 59


A --H-
Fig. 15. Power transmission structure Fig. 16. Power transmission structure
(Florida Utility Company). (Eugene Water and Electric Board).

Fig. 17. Power transmission structure


(Virginia Electric and Power Company
Currituck Sound Crossing). Built in 1964,
these tapered I-shaped prestressed
concrete poles were used to upgrade a
34.5 to 11.5 kV, 3 mile (4.8 km) water
crossing in North Carolina. The poles were
manufactured using the centrifugally-spun
cylinder pile method.
DESIGN LOADINGS wind span is unaffected by terrain and
will always he half the true horizontal
Pole structures have to be designed to distances between suspension struc-
be reliable, serviceable, and to resist tures.
(without permanent distortion) all an- Selection of the ice loads should be
ticipated maximum service loads. In the based on experience records for each
United States, the loading conditions for service area; these records can be ob-
electric power structures have to meet tained from the U.S. Weather Bureau.
or exceed those given in the National Ice build-up may not be the same on all
Electrical Safety Code (NESC). For spans, and the engineer should recog-
lighting structures, the loading condi- nize this effect when designing for un-
tions have to meet or exceed the NESC balanced longitudinal loads.
andlor AASHTO Standard Specifica- During the wire stringing operation,
tions for Structural Support for Highway the structure may receive vertical loads
Signs, Luminaires, and Traffic Signals. more severe than those in normal design
For microwave or antenna towers, the loadings.
loading conditions have to meet or ex- For maintenance loads, the structure
ceed the Electronic Industries Associa- should be designed to provide adequate
tion Standard RS-222-C. support for conductors that are being
These loadings are minimum re- lowered during a repair operation. This
quirements and the designer's study of is often overlooked and could be a criti-
the structure location will determine cal factor for a light structure.
whether these minimum requirements Transverse loads are caused by (1)
should be increased. Loads other than wind pressure on the structure and
those required by the codes or standards wires and (2) the transverse component
that affect the design of these structures of line tension at angles. In combining
are those due to extreme weather, or to these loads to give a total transverse de-
manufacturing, handling, transportation, sign loading, it is important to ensure
and erection. that the appropriate conductor tension
be used with the corresponding wind
Electric Power Transmission load.
Structures Extreme wind forces on transmission
lines may be caused by three funda-
In these types of structures the design mentally different types of meteorologi-
loadings are due to (1) vertical loads, (2) cal systems: (1) tornadoes, (2) hur-
transverse loads, and (3) longitudinal ricanes, and (3) local thunderstorms.
loads. A tornadic wind is a type of a
In addition to their own weight, whirlwind with rotating wind velocities
structures are subjected to vertical loads estimated at well over 200 mph (322
due to dead loads of wire and attach- kmlh). Tornadoes have velocities and
ments, and ice. The only variable here is accompanying pressures so great that
the ice. A structure should be designed they destroy everything before them,
for vertical loads due to maximum verti- but fortunately they take narrow paths
cal span, ice, construction, and mainte- and, as a rule, do not last long. Reported
nance loads. losses of transmission structures in a
The maximum vertical span depends tornado are usually small, typically only
on the terrain. Structures located on one to six structures for each strike. En-
hills must support more wire load, low gineers generally agree that it is un-
point to low point of wire sag, than the economical to design structures to resist
adjacent structures which are located on tornadoes.
level ground (Fig. 18). The horizontal A hurricane is a very violent

PC! JOURNALISeptember-October 1984 61


V

V IV2

VERTICAL SEMISPANS

Fig. 18. Vertical and horizontal design spans for pole structure,

windstorm out of the West Indies; these ical area by using the annual extreme
windstorms usually blow up in summer fastest-mile wind charts developed by
and fall of the year. On the Beaufort the U.S. Department of Commerce—
scale, winds of over 75 mph (121 krn/h) Environmental Science Service Ad-
are classed as hurricane winds. The ministration using statistical prob-
storm usually starts as a tropical depres- ability.
sion in the Atlantic Ocean. As it moves Charts are available for elevations of
along its path, the counter-clockwise 30, 60, and 90 ft (9, 18, and 27 m) above
winds around the center grow in inten- ground, in varying mean-recurrence
sity in the area covered. Winds of 100 to intervals. To realize what these charts
120 mph (161 to 193 km/h) are common, are, consider the wind velocity record of
Hurricanes cause great destruction each Fig. 19. It represents a 5 minute wind
year to parts of the Caribbean Islands, variation at the location of a certain
Gulf, and East Coast States. In the structure during the most severe storm
Pacific Ocean, these storms are called of a given year.
typhoons. Engineers in the areas af- The 5 minute average and the peak
fected by hurricanes have to pick a de- 2-second gust are self-explanatory. The
sign for extreme wind speed that is a fastest mile is defined as the average
balance between risk of failure and velocity at which 1 mile (1.6 km) of air
structure cost. passes the anemometer.
Thunderstorms and squall lines are The operational life of the transmis-
more localized and random in their im- sion line should determine the mean re-
pact and are the main concern of en- currence interval chart that is used.
gineers in most parts of the country. Utilities normally consider the life of a
To determine the design wind load, wood pole line at about 25 to 30 years,
the engineer needs to know a design steel and prestressed concrete structural
wind velocity and a suitable equation by lines at about 60 years. It is recom-
which it can be converted to pressure on mended that a 50-year mean recurrence
the transmission line. The design wind interval be used for prestressed concrete
loads may be determined for a geograph- structure lines.

62

VELOCITY AT A I PEAK GUST OF 2Sv

—FASTEST MILE OR IM v

I I 1 ^
1 11 1

O 4 - I MIN.
5 MIN.

Fig- 19. Wind velocity strip graph for designing pole structure.

A well-known formula for increasing Wind Pressure on Structures


wind speed according to height is:
There appears to be general agree-
) lIn (1) ment that short wind gusts are large
V V ^ h enough to envelop a transmission
n= ^ 0
structure. For this reason, the design
where wind pressure on a transmission struc-
V,, = adjusted velocity, mph ture should be determined from a gust
V. = annual extreme fastest mile velocity. Relationships between peak
wind chart velocity, mph gust and fastest mile have been de-
h = adjusted elevation, ft veloped; one such expression used by
ho = elevation ofVa , ft the industry is:
n = constant dependent on surface
roughness (varies from 2 to 7) Peak gust = 1.3 x Fastest mile (4)
A value of 7 for n is normally used for To find the design wind pressure on a
level or slightly rolling land with scat- transmission structure, the wind pres-
tered trees or buildings. The formula is sure formula should be adjusted to:
not reliable for use in decreasing wind
speeds below 30 ft (9 in). Wind velocity, P = k (1.3V)2 (5)
in mph, may be converted into wind
pressure by using the following formula: where k is the surface shape coefficient.
For wind pressures on cylindrical The same problems of selecting wind
surfaces: velocity and suitable equations also
arise with regard to the transmission
P = 0.0025 V $ (2) line. It has been mentioned that a short
gust of wind could envelop a structure,
For wind presures on flat surfaces: but it cannot envelop a span oftransmis-
P = 0.0042 V 2 (3) sion line approximately 1000 ft (305 m)
in length. Field tests have shown that a
where reduction factor can be applied to mod-
P = wind pressure, psf, on projected ify the conventional drag coefficients in
area of surface picking a wind pressure on a conductor.
V = design wind velocity, mph After the conductor design pressure has

PCI JOURNALJSeptember-October 1984 63


been determined, an effective wind In areas of moderate to heavy ice
span factor (fP,,) of 0.6 should be loadings, this transverse component will
applied to all spans in excess of 1000 H. tend to control the design of angle and
For span lengths between 300 and 1000 dead end structures. In areas of no ice,
R (91 and 305 m), this factor will vary or where only minor icing occurs, care
and should be determined as follows: should be taken in determining the ef-
= 1.0 – 0.4 (S – 300)/700 (6) fect of wind on line tension, being sure
to use the same design wind velocity to
where S is the span length, ft. calculate line tension as is used to cal-
culate the strength of the structure. Care
For spans of 300 ft (91 m) or less, the is necessary also in calculating which of
effective wind span factor should be 1.0. these two "maximum" conditions is
Extreme wind with heavy ice is critical:
another condition the engineer has to 1. Maximum wind velocity with cor-
consider. Maximum winds that occur responding line tension
during sleet storms are usually lower in 2. Maximum line tension with corre-
intensity than winds at other times in sponding wind velocity
the same area. The engineer must re-
view local weather records to determine
the range of wind velocities that occur Longitudinal Loading
during freezing precipitation. Then, For years, transmission structures
using the appropriate ice loading, he have been designed using a longitudinal
must calculate whether the wind-with- loading condition of a broken conductor
ice condition is more critical as a trans- and/or overhead shield wire dead load.
verse load than the higher wind on bare In recent years, the trend has been to
conductors. use larger conductors, and many utilities
A study made in Canada of maximum have regarded the broken wire condi-
wind recorded during freezing precipi- tion as being too conservative.
tation and for one day after, tabulated Longitudinal loads can he imposed on
local variation. This technique is valu- structures by many conditions other
able for the engineer because data can than broken wires. The following are
be taken directly from weather records, several other conditions under which a
thus showing winds which are likely to structure will he subjected to longitudi-
occur in a given area when there is ice nal loadings:
on the conductor. 1. Conductor or overhead shield wire
stringing loads
Transverse Loads and Line Angles 2. Unequal spans
3. Wind parallel to the line
The transverse loading upon the 4. Wind at 45 deg to the line
structure must be taken as the resultant 5. Ice-unloading unbalance
load equal to the vector sum of the 6. Loss of an adjacent structure
transverse wind load and the resultant During stringing operations there are
load imposed by the wires due to their instances where the stringing block may
change in direction. In deriving these jam momentarily, or a sleeve passing
loadings, a wind direction must be taken through the block may "hang up,"
which will give the maximum resultant causing some longitudinal load to be
load. Proper reduction is made in load- applied to the structure. Stringing
ing to account for the reduced wind equipment located too close to a struc-
pressure on the wires resulting from the ture may impose detrimental vertical
angularity of the application of the wind and longitudinal loads to the structure
to the wires. during wire stringing operations.

64
Table 1. Overload capacity factors for metal and prestressed
concrete structures (NESC Table 261-2).
Overload capacity factors
Strength Grade B Grade C
Vertical strength 1.50 1.10
Transverse strength 2.50 2.20
Longitudinal strength
At crossings
In general 1.10 No requirement
At dead ends 1.65 1.10
Elsewhere
In general 1.10 No requirement
At dead ends 1.65 1.10

Note: The factors in this table apply for the loading conditions of NESC
Rule 250B. For extreme wind loading conditions, Sec NESC Rule 260C.

In mountains or very hilly areas, it is these chunks fall from one span, the
possible to have longitudinal loads swing of the insulator strings in a lon-
caused by unequal spans. This is due to gitudinal direction is noted. This has led
the difference in tension in the wires in designers to use only a percentage of the
adjacent spans resulting from unequal ice-no-ice tension differential as the
vertical loading and/or unequal span longitudinal loading. The longer the in-
length. sulator string, the more the tension dif-
Winds not only blow on the structures ferential is reduced.
in the transverse direction, but in the Under Section 25, the NESC sets the
longitudinal direction and at all angles minimum weather loading condition for
in between. The structures should at a which a transmission line is to he de-
minimum be designed to withstand the signed. These minimum weather load-
wind plus gust which may envelop it in ings must be values of loading resulting
the longitudinal direction. Winds from the application of Rule 250-B -
blowing at 45 deg to the line can exert Combined Ice and Wind Loading or
longitudinal forces on the structure due Rule 250-C — Extreme Wind Loading,
to wind on the wires and wind on the whichever is the greater.
,,tructure itself. These longitudinal In the design of pole structures, the
forces should be investigated. term "overload capacity factors" is in-
Ice -unloading unbalance is now the terpreted to mean that the structure
most commonly used longitudinal should support, without permanent set,
loading. The dropping of ice from one or the maximum loadings to which it will
more wires in different combinations is be subjected multiplied by the appro-
used by a designer to provide torsional priate overload factors,
strength in addition to longitudinal The general loading requirements set
strength in a structure. forth in Section 25 of the NESC are to be
Ice may build up on wires in only a multiplied by overload Factors set forth
few spans causing longitudinal loads. In in Section 26, "Strength Requirements"
most cases, ice builds fairly uniformly depending on type of structure, to es-
on all spans, and usually drops from one tablish the design loads (see Table 1).
span before another. Ice frequently falls The minimum strength of any pole
in large chunks when it starts to melt. As structure must be sufficient to with-

PCI JOURNALJSeptember-October 1984 65


The following loads are typical of
those usually considered:
T^
1. Vertical Loads
Hif A. Weights of bare wires plus in-
sulators at attachment points
Hz1 B. Weights of wires coated with
f
1 radial in. (13 mm) ice plus in-
T2 sulators at attachment points
C. Weights of wires coated with 1 in.
(25 mm) radial ice plus insulators
Fig. 20. Line angle loads acting at attachment points
on pole structure. Note: D. One man plus equipment at criti-
Line angle load = H, + HZ. cal points
E. Vertical components of stringing
loads
Loads A, B, and C are calculated as
the product of the weight of wires
stand, without conductors, the extreme (coated or not) per unit length by the
wind pressure in Rule 252 applied in vertical span V.
any direction of the structure, multi-
plied by an overload capacity factor of 2. Transverse Loads (Fig. 20)
1.0. A gust factor appropriate for the F. Line angle loads from bare wires
wind pressure and structure height subjected to extreme wind, fastest
should be considered. mile at 60F(16C).
The overload factors for prestressed G. Line angle loads from Vs in. (13
concrete pole structures as set forth in mm) ice coated wires subjected to
Section 26 of the NESC are shown in 40 mph (64 km/h) wind at 0 F (-18
Table 1.
C) [4 psf (0.19 kPa) wind prssure]
The transmission line designer, as can H. Line angle loads from wires
be seen, starts with the NESC recom- coated with I in. (25 mm) ice at 0 F
mended load schedule for geographic (-18 C)
area in which the line will be built. I. Transverse force on structure due
Following this procedure, combinations to 40 mph (60 km/h) wind [6.4 psf
of wind, ice and dead loads are added (0.3 kPa) wind pressure I
based on local weather conditions, past J. Transverse force on structure due
experience, and historical precedence. to extreme wind (say 1.3 x fastest
To each of the contingencies, overload mile)
factors are applied to weigh the impor- K. Transverse forces at attachment
tance of that particular contingency points due to 40 mph (64 km/h)
under the site's unique conditions. wind on wires coated with 1 in. (25
The designer of the structure, must mm) ice
examine all these loading conditions, L. Transverse forces at attachment
since different loads will control indi- points due to extreme wind (say
vidual members or sections of the fin- 1.3 x fastest mile) on wires
ished structure design. M. Transverse component of force on
For design purposes, all wire loads on structure due to diagonal extreme
a transmission structure are considered wind
to be concentrated loads with a trans-
verse, longitudinal and vertical compo- Loads F, G, H, and I can be deter-
nent. mined as algebraic sums of the trans-

66
verse components of tensions of at-
tached wires. vs
Note that transverse forces K and L
are the products of wind forces per unit -- Ts
length of wire by appropriate wind
spans.
fr ç
3. Longitudinal Loads
N. Unbalanced wire tensions due to L^
unequal vertical loads, different ^v --r T
span configurations, etc. —
W V
0. Longitudinal force on structure
from extreme wind (say 1.3 x fast-
est mile)
T = transverse load
P. Longitudinal component of force L = longitudinal load
on towers from diagonal extreme V = vertical load
wind w = wind on structure
Q. Longitudinal component of V, . L, T, = shield wire loads
stringing and construction loads
R. Broken wires — Loads should re- Fig. 21. Design loads ("load tree")
flect experience under actuaI con- acting on pole structure.
ditions
S. Ice-unloading unbalance — Ice-
no-ice tension differential x per-
cent reduction due to insulator
swing Heavy Ice
T. Dead-end tensions from bare ca- Case I11 1.50 (C) 1.1 (H)
bles subjected to extreme wind at (Vertical load) (Transverse load)
60F(16C) 1.1(S)
U. Dead-end tensions from ;/s in. (13 (Longitudinal load)
mm) ice coated wires subjected to
40 mph (64 km/h) wind at 0 F (-18 The above are the basic loading cases.
C) This is the procedure the utility en-
V. Dead-end tensions from 1 in. (25 gineer goes through in supplying the
mm) ice coated wires at 0 F (-18 designer with the "load trees" (Fig. 21)
C) required to design prestressed concrete
pole structures.
Design loads for prestressed concrete
structures are ultimate loads. The fol-
lowing design loading conditions, load Lighting Structures
multiplied by overhead capacity factor,
can be used at overhead shield wire and Lighting pole structures must meet or
conductor points: exceed the design loadings of the NESC
and/or AASHTO Standard Specifica-
NESC — Heavy Loading tions for Structural Supports for High-
Case I 1.50 (B) 2.50(K) + 1.65 (G) way Signs, Luminaires and Traffic Sig-
(Vertical load) (Transverse load) nals, and include (1) dead load, (2) live
load, (3) ice load, and (4) wind load.
Extreme wind In addition to its own weight, the
Case II 1.50 (A) 1.1 (L) + 1.1 (F) dead load includes all permanently at-
(Vertical load) (Transverse load) tached fixtures, including hoisting de-

PCI JOURNAL/September-October 1984 67


vices and walkways provided for ser- lighting, climbing facilities, platforms
vicing of luminaires, if required. and signs.
Live load need not be applied to The ice load is based on solid ice
structural supporting members. The [density of 56 pef (897 kg/m s) J applied to
only member requiring a live load de- the attached fixtures. This standard does
sign would be the walkway and ladders. not specifically state an ice thickness
The ice load of 3 psf (0.14 kPa) is required. Consideration to its location
applied only to the attached fixtures, and the climatic conditions should he
ladders, walkways, luminaires or signs, given to an ice thickness requirement in
and is based on 0.50 in. (13 mm) of ice at preparing the specifications.
60 pef (961 kg/ms). Wind loads are defined as the force
Wind speeds are based on the 25-year and torques produced by a specified
mean recurrence interval wind speed unit horizontal wind pressure acting on
maps developed by the U.S. Depart- the tower, antenna assemblies, reflec-
ment of Commerce — Environmental tors, and other fixtures attached. In all
Science Service Administration and cases, the specified ice coating should
adjusted for height. Wind pressure on be included as part of the projected area.
structural supports is computed from: Minimum horizontal wind pressure in
pounds per square foot (psf) are referred
P = 0.00256 (1.3V)2 C d C, (7) to on a map chart called "Wind Loading
where Zones" which is part of the standard.
Cd = a dimensionless drag coeffi- For towers under 300 ft (92 m), Zone A
cient that varies with the shape —30 psf(1.4 kPa); Zone B — 40 psf (1.9
of the support structure re- kPa); Zone C — 50 psf (2.4 kPa); the
ceiving the wind loading pressure is assumed to be applied uni-
C„ = coefficient of height, derived formly over the entire height of the
from (H/30)1-T structure.
H = height at which pressure is de- Tower twist is defined as the hori-
termined zontal angular displacement of the
V = wind speed at 30 ft (9 m) height tower from its no wind load position at
1.3 = gust factor that elevation. Tower sway is defined as
The wind load on the structure must the angular displacement of a tangent to
be determined by the areas of horizontal the tower axis at that elevation from its
and vertical supports, luminaires and no wind load position at that elevation.
signals and must be applied to the sur- Tower displacement at any elevation is
face area seen in normal elevation. defined as the horizontal displacement
of a point on the tower axis from its no
wind load position at that elevation.
Antenna Support Structures
A table of allowable twist and sway
values for microwave tower-antenna-
Antenna support structures must meet reflector systems is attached to the
or exceed the design loads of the Elec- .standard.
tronic Industries Association, EIA Stan-
dard RS-222 latest revision, and include Shape
(1) dead load, (2) ice load, (3) wind load,
and (4) limit values of twist, sway, and The shape of poles has a bearing on
displacement. the design and manufacturing
In addition to its own weight, the technique. The normal sections adopted
dead load includes all permanently at- in various countries are shown in Fig.
tached fixtures, antenna assemblies, 22. The simplicity of the square and
transmission lines, reflectors, conduits, rectangular solid section poles of small

68
OH

Hll-(
Fig. 22. Typical cross sections of prestressed concrete poles.

length, up to 40 ft (12 m), make them DESIGN CRITERIA


easy to manufacture, facilitate position-
ing of steel at corners giving maximum Design criteria for poles vary signifi-
resisting moment for a given depth, and cantly from country to country. How-
occupy less space in transportation. Cir- ever, poles generally act as a cantile-
cular hollow sections seem to be ideal vered structure, and should be designed
for the longer poles. and/or analyzed as a tapered member
Cylindrical hollow poles have these with combined axial and bending loads.
advantages: less weight; equal strength The shear forces are very small when
in all directions eliminating any special compared to the bending moments; the
care during handling, transportation and deflections are relatively large, and this
erection; a denser and higher quality of helps to provide the resilience. The
concrete from the spinning process. The axial loads, being small, are generally
absence of corners and the smooth, ignored except when the structure is
dense minimum surface area give guyed.
greater protection against corrosion fail- It is essential in the design to examine
ure. However, there is a considerable the stresses induced by handling, trans-
divergence of opinion concerning the portation and erection. Under severe
best shape of a pole. conditions of handling, these may ex-
Vierendeel poles are also widely ceed in-service stresses. The stresses
used. Their use has been in structures of imposed during transportation will de-
33 ft (10 m) in length and above and pend on the method of transportation
where higher transverse loads are in- available. The common lifting points
volved. They have the disadvantages of used are the third points or, in some
having larger exposed areas and thin cases, the center of gravity. Erection
elements, leading to possible concrete stresses will likewise depend on the
cracking and corrosion. It should be point at which the pole is lifted. In con-
noted that if the horizontals are not sidering the latter, the weight of the
spaced further apart, they will be mis- cross-arm and/or other attachments
used for climbing. East European coun- should not be overlooked in calculating
tries have used the Vierendeel pole in a the position of the center of gravity.
"Pi" structure or H-frame structure for The concrete structure should be
carrying transmission lines. proportioned so that the deflection due

PCI JOURNAL1September-October 1984 69


to the service loads will not he detri- bond or by dead-ending some of the
mental to the strength, serviceability re- tendons along the length of the pole.
quirements, and the aesthetic qualities Another design factor is the flexural
of the structure. moment that causes initial cracking on
The pole has to withstand equal the tension face of the pole. This is the
bending moments in opposite directions point at which all the prestress and the
and therefore concentric prestressing is tension capacity of the concrete has
provided. Hence, the magnitude of the been used. This has been found to be
prestress can only be about one-half of about one-half of the ultimate moment
the value that can be used for bending in of the fully prestressed sections. The
one direction. This is an important dif- design permits the pole to exceed the
ference in the design of prestressed cracking moment, but not to fail under
concrete poles compared to other types ultimate design conditions.
of prestressed structures. So far the paper has concentrated
The ultimate moment capacity of the upon fully prestressed concrete poles,
pole at various sections is a function of but some of the larger poles used for
the strains of prestressing steel and con- transmission line structures in Europe
crete and the effective stresses in the and India are partially prestressed. The
prestressing steel. Loaded to failure, the definition of each follows:
pole will fail in one of the following Full Prestressing — A concrete
modes at the section which undergoes a structure is fully prestressed if the
higher ratio of bending design moment stresses due to bending perpendicular
to ultimate moment capacity. to the direction of prestressing calcu-
1. Rupture of steel — The pole might lated for the full design service load are
have one or more sections having a compressive. (It should be noted that
low percentage of steel, i.e., full prestressing does not provide abso-
under-reinforced sections. The ul- lute safety against tensile stresses or
timate strength of the steel is at- cracking due to shear, torsion, temper-
tained before the concrete has ature effects or imposed deformations.)
reached a highly plastic state. Partial Prestressing — A concrete
2. Crushing of concrete — The pole structure is partially prestressed if sub-
might have one or more sections stantial tensile stresses or cracks per-
having a high percentage of steel, pendicular to the direction of pre-
i.e., over-reinforced sections. The stressing can occur in the concrete
steel stresses do not exceed the under the full design service load. Such
yield point, and failure results in cracks may be of limited width to satisfy
the crushing of concrete. durability or appearance purposes. (In
3. Failure of both steel and concrete these cases, additional mild steel rein-
— Sections of the pole may have a forcement is added in the direction of
balanced behavior of the two mate- the tendons to meet ultimate strength
rials. The steel would he stressed requirements.)
into the plastic range and the con- Reinforced Concrete — A reinforced
crete would attain the maximum concrete structure is one in which none
strain defined by its capability. of the steel reinforcement is prestressed
To achieve the balanced behavior in during construction.
the third failure mode in a tapered pole The full design service load is the
presents a practical problem regarding equivalent of the design loading before
the application of prestress. However, the applicable code overload capacity
systems have been developed to reduce factors have been applied.
the effective prestress in the upper por- Partially prestressed poles will con-
tions of the tapered pole by preventing tain both prestressing tendons and mild

70
steel reinforcement. The reinforcement sentially of three stages:
should have high bond characteristics. 1. Assessment of prestressing force to
The degree of prestressing will influ- satisfy serviceability requirements
ence the behavior of the structure under under permanent or frequently oc-
service loading with regard to deflec- curring load.
tion, tensile stresses and cracking, and 2. Assessment of ultimate strength of
all of the steel will operate to provide an member (in bending, shear, etc.).
adequate factor of resistance at the ulti- 3. Checking cracking and deflection
mate stage. conditions under the maximum
The service load should be consid- possible service load.
ered in two parts: It is necessary to control the extent of
(a) That portion of the load which is cracking at serviceability conditions in
permanently or frequently occur- order to ensure durability of the steel
ring. against corrosion and to ensure an ac-
(b) The maximum possible service ceptable surface appearance. The de-
load which may be applied. gree of cracking which can be allowed
In Condition (a) the prestress should must depend on the aggressiveness of
be such that control is exercised in one the environment to which the structure
or more of the following ways: will be subjected, and the quality of the
1. Control of cracking, either no concrete being used.
cracks or crack width limited to a In designing prestressed concrete
defined amount, poles by the codes of different countries,
2. Control of concrete bending ten- a certain cracking resistance under sus-
sile stress in the section under tained loads is specified, though the
load, either no tension or a defined loads and requirements about the ad-
maximum tensile stress transverse missibility of cracks differ. The methods
to the direction of prestressing. of controlling strength, rigidity, and the
Stress created by secondary mo- prestress in the steel and the concrete
ments may also need to he consid- differ as well. In view of this, it is dif-
ered. ficult to compare the efficiency of poles
3. Control of deflection, zero deflec- used in different countries.
tion or a defined maximum value, In East Germany, poles are designed
positive or negative, in relation to by the ultimate load method for State 2
the span. to provide a prestressing value compati-
For Condition (h) it should he ac- ble with the allowable crack width
cepted that cracks occur and the under the average and maximum loads.
member deflects more than under Con- The design is based on the regulations
dition (a) loading, but these cracks will in TCL 0-4227 and TCL 112-0491.
close and the deflection will reduce on In West Germany, the loads on poles,
removal of the load. It must be ensured their interaction under various working
that the structure will return to a condi- conditions and the design methods are
tion complying with the requirements based on a number of documents in
for Condition (a) when the infrequent force, including: DIN 4228-1964, DIN
load is removed. Investigations at Con- 48353, DIN 1055, VDE 0210/5.62, and
dition (h), therefore, need only be such DIN 4227. Checks on stresses are made
as to ensure that the structure returns to under average and exceptional loading
these conditions and perhaps that no ex- cases. The standard design restricts the
cessive deflection will occur under this crack width to less than 0.1 mm (0.004
maximum load. in,) with a spacing of about 100 mm (4
The design basis for partially pre- in.).
stressed poles consists, therefore, es- In the Soviet Union, poles are de-

PCI JOURNAUSeptember-October 1984 71


Table 2. Comparison of various provisions for different codes of practice.
Germany India United Kingdom
Poles Czechoslovakia DIN 4227/4228 IS 1678 Japan New Zealand BS 607
Load factor LO 1.5 1.2 1.0 — 1.2
against crack Crack width
under design
load 0.25 mm
Load factor 2.0 1.75 2.5 2.5 — 2.5
against failure
Equivalent load 10 in. (250 mm) — 24 in, (600 mm) 10 in. (250 min) 12 in. (300 mm) 24 in. (600 min)
applied at from top
Embedment length 0.2 of height 0.2 of height 4 to 8 ft 6.5 ft (2.0 m) 7.22 ft (2.2 m) 4 to SR
(1.2to2.4m) (1.2to2.4m)
Concrete strength 7100 psi 10,000 psi Above 6000 psi Above 4500 psi Above 5700 psi Above 6000 psi
(50 MPa) (70 MPa) (42 MPa) (.38 41 Pa) (40 MPa) (42 MPa)
signed in accordance with the relevant same functions and operating under
standards and codes using the limit state substantially identical conditions.
method (SNiP I1-C.1-62, SNiP II-1.9-62
and others). Design by strength, defor-
mation as well as crack width are cov- MANUFACTURE
ered by this method, The first limit The successful manufacture of pre-
state, ultimate strength, must always be stressed concrete poles depends on the
checked. The second limit state needs local conditions and available equip-
only to check the behavior of terminal ment. It can be done in specialized fac-
poles under emergencies. The third tories using the sophisticated spinning
limit state requires the behavior of every method with steam and/or water tank
concrete member to be checked for curing, or as in India, in remote areas on
normal service loads. site locations, using portable preten-
In the United States at this time, it is sioning beds, local untrained labor, air
recommended that prestressed concrete curing and specially designed bullock
poles be analyzed for ultimate strength carts for transporting and erecting the
in accordance with the basic provisions poles. The following are the principal
given in the Building Code Require- manufacturing methods.
ments for Reinforced Concrete, ACI
1. Industrial manufacturing of com-
318-83, modified to include the effects
plete poles at specialized factories:
of prestressing. Pole structures should
(a) By centrifugal casting method
be designed to withstand the maximum with demountable steel forms;
of the forementioned loading condi-
(b) By vibration, compacting on a
tions, including the overload factors,
bed with the molds laid hori-
without exceeding the ultimate strength
zontally;
of the pole. Under normal working con-
(c) By compaction in a machine
ditions, the design should not exceed
with either transverse or lon-
the cracking moment.
gitudinal vibration.
In Canada under the proposed new
CSA Standard A14-M, Concrete Poles, 2. Manufacture may be on site with
poles may be designed in accordance poles placed horizontally.
with CSA Standard A23-3, Design of 3. Poles may he made from precast
Concrete Structures for Buildings, with- sections which are assembled on
out recourse to classification testing, site by post-tensioning or by
provided that substantive information is splicing, or may be partly preas-
available for presentation to verify that sembled in special casting yards.
the poles, as manufactured, are in accor- In most of Europe and Japan, concrete
dance with the design assumptions. poles are economically mass produced
Poles may also he designed using em- by well equipped plants using the cen-
pirical coefficients obtained from clas- trifugal casting method. The basic man-
sification tests, conducted in accordance ufacturing equipment needed is the
with Clause 7 — Classification Testing spinning machine and the steel forms.
Procedures and within some stated The spinning machines are of heavy-
limitations. duty, roll-bench type and have sets of
Table 2 compares the major provi- spinning wheel assemblies at 10 Ft (3 m)
sions of the various codes of practice and intervals. The spinning wheel as-
lists some of the basic code require- semblies are hard face, long wearing
ments. wheels mounted on extra large anti-
It would be helpful to have some in- friction rollers and ball bearings in to-
ternational standardization of design tally sealed pillow blocks. The machine
methods for pole structures fulfilling the is normally driven by a full length

PCI JOURNAL/September-October 1984 73


drive-shaft with ball type universal
joints and a single drive station located
at the middle of the machine. Some of
the more modern machines are
equipped with automatic form loader!
unloader for maximum efficiency.
The demountable steel forms usually
consist of two halves, but some plants
use a single piece form. These forms are
made in 10 ft (3 m) sections and are
bolted end to end to the required pole
length. The forms are precision de-
signed and built for ruggedness; they
are statically and dynamically balanced
for smooth, vibration-free running.
Forms are available in a wide range of
sizes, lengths and shapes. The usual
shape is round with a uniform taper from
top to bottom. Other shapes used are
hexagonal, octagonal, square with
chamfered corners, triangular with
chamfered edges, and cylindrical. They
are normally tapered to any dimension
from 0.15 to 0.180 in./ft (12.5 to 15
Fig. 23. Open from concrete placement mm/m).
(with reinforcement in place) used in The process of making a spun con-
manufacture of prestressed poles. crete pole is to lay out the oiled lower

ii:

Fig. 24 Closed form concrete placement used in manufacture of poles.

74
Fig. 25. Closed form concrete placement used in manufacture of poles.

half of the form, to place full length spi- lated amount of concrete and final pre-
ral wire wrap, to pull reinforcing strand stressing takes place after the form has
or wire through spiral wrap to anchor been filled and fully assembled. In
heads, then to chuck and apply a small plants using "closed form filling" (Figs.
amount of stress, In plants using "open 24 and 25), the form is closed irn-
form filling" (Fig. 23), the form is closed mediately after placing the reinforce-
after it has been filled with a precalcu- ment, final prestressing takes place after

Fig. 26. Pole spinning operation.

PCI JOURNALiSeptember-October 1984 75


Fig. 27. Pole manufacture in India using Hoyer's long line method.

the form has been fully assembled, but dressed up and air cured for 28 days
before a precalculated amount of con- before shipping.
crete is pumped or dumped into it. The Swiss BBRV prestressing system
The form is then placed on the spin- is also being applied to the manufacture
ning machine where it is spun for sev- of poles. In this system high tensile wire
eral minutes. Two speeds are used in is anchored at the pole ends by means of
the process. At the lower speed, the button heads and special anchor
mixture is divided uniformly along the washers. Using this system and some
form and the cylindrical cross section is special auxiliary equipment, spun con-
formed. At the high speed, the tremen- crete poles are being made for electric
dous centrifugal force created by spin- power lines.
ning extracts excess water and consoli- Vibration techniques are widely
dates the mix to an extremely dense, applied in the manufacture of concrete
high strength concrete (Fig. 26). poles. In East Germany, a vibration
After spinning, the form is taken to the method known as Mensel's method is
steam curing area, where the pole is used where lightweight horizontal
cured with low pressure steam for a molds are carried on mobile frames
period of time until the strength of the strong enough to take the tensile
concrete in the pole has attained at least stresses of the prestressing steel, A
3500 psi (24 MPa). The prestressed wire production line system is used, and the
or strand is then released; the pole is molds and equipment circulate so that

76
the workers do not have to move around. MATERIALS
The production system embraces some
of the processes used with other The strength of concrete and pre-
methods of production and includes one stressing steel varies in different coun-
special feature. A formwork core oc- tries. Specified values for various coun-
cupies the space which will be the inner tries are shown in Table 3.
cavity of the pole, and this is rotated a In general, prestressed concrete poles
little after the concrete has begun to are made from dense concrete with a
harden. It is removed when the concrete 28-day strength of 3000 to 8500 psi (21 to
has fully hardened. With this method of 59 MPa). Some poles have been made
production, curing is done by a heat with 10,000 psi (69 MPa), and in the
treatment cycle. The temperature of the United States one supplier is using
poles is raised to 163 F (73 C), held and 12,000 psi (83 MPa) concrete.
then cooled during a 24-hour period. Tendons for prestressed concrete
The most common casting method for poles are usually one of the following:
solid sections (square, rectangular, High strength, cold-drawn or heat-
channeled, I or Y shaped) is the long treated deformed wire with circular or
line method. In India it is called Hoyer's oval sections; seven-wire strands of a
long line method. The forms are placed smooth round wire; bundles of several
end to end along the length of the bed, similar wires; deformed bars made of a
300 to 400 ft (90 to 120 m), with the nar- hot-rolled low-alloy or heat treated
row ends of the tapered poles facing steel.
each other and the wide ends next to The mechanical properties, type and
each other (Fig, 27). The prestressing classes of steel vary from country to
wire or strand is positioned by means of country and should be determined by
the holes in the bulkheads and is pre- appropriate regulations, standards and
tensioned against end abutments. The technical specifications (Table 3).
concrete is then fed into the forms and
compacted with external vibrators TESTING
operating at about 6000 cycles per min-
ute. Two types of testing are used to de-
In India steam curing is not generally termine the flexural behavior and
adopted. The design of the concrete mix flexural capacity of poles under static
is such that the stress at transfer is ob- loading conditions: pole testing and
tained at the end of 3 days when wires or structure testing.
strands are cut and the mold released. In Pole testing is used to verify the de-
other countries the forms are covered sign and quality of production of the
and steam cured for about 24 hours, with poles. A test frame such as that shown in
a concrete release strength of 4000 psi Figs. 28 and 31 is used. Here, the butt of
(28 MPa). Poles made by the long line the pole is fixed and the pole is pulled
method can be made in any precast con- from a point below the tip, usually 2 ft
crete yard, or on site. (0.6 in), about a reaction point ground-
In the United States today, the limited line distance from the butt. By adding
number of prestressed concrete poles the load in increments of the ultimate
being made for lighting and for power design, the cracking moment and physi-
transmission and distribution are made cal behavior of the pole to destruction
by the long line method or the cen- can he checked. It is good practice to
trifugal casting method. Currently, in include in the specifications some ran-
Canada all plants are making pre- dom pole testing to a percentage of the
stressed concrete poles by the cen- ultimate strength of the pole as a qual-
trifugal casting method. ity assurance check. A pole can be tested

PC[ JOURNAL/September-October 1984 77


v
00

Table 3. Materials used for manufacturing prestressed concrete poles.


Concrete Prestressing steel Nonprestressed steel
Compressive Ultimate Compressive
strength, psi strength, psi strength, psi
County (MPa) Type Type (MPa) Section and shape Type (MPa)
Czechoslovakia 7100 Normal ST 140/175 250,000 (6 mm)
V4 in.
(50) concrete (1716) Round
France 5500-8500 Normal ST 140/160 230,000 Plain
(40-60) concrete (1569) round
0.03-0.062 in.s
East Germany 6400-8500 Normal ST 1401175 230,000 (20-40 mm2) Deformed 57000-71000
(45-60) concrete (1569) Deformed oval ST III (392-490)
0.03-0.06 in.'
West Germany 4200-10000 Normal ST 140/175 230,000 (20-40 mm 2) Deformed 57000-71000
(30-69) concrete (1569) Deformed oval ST 11I (392-490)
4a-fie in.
India 6000-7500 Normal Indented and 230,000-255.000 (3.25-4.5 mm)
(42-52) concrete plain round (1569-1765) Indented and
plain round
5/18 k8 in.
Japan 7100 Normal J15G3109 193,000 (8-16 mm)
(88) concrete (1334) Bound deformed
Table 3 (cont.). Materials used for manufacturing prestressed concrete poles.
Concrete Prestressing steel Nonprestressed stecl
Compressive Ultimate Compressive
strength, psi strength, psi strength, psi
Country (MPa) Type Type (MPa) Section and shape Type (MPa)

Hard drawn V1€-Y2 in.


New Zealand 5500 Normal high tensile 192,000 (5-12,7 mm)
(38) concrete steel wire (1373) Round
Poland/Romania 3000-8500 Normal ST 1401160 230,000 Plain round
(20-60) concrete (1569)

United Kingdom 6000 Normal Plain and 213,000 Ne, Otis, and "ti in.
(42) concrete hard drawn (1471) (3.25, 4.5, and 7 mm)
steel wire
3000-900 Nonrial Vr-II 227,0011-241,000 '/a2, and ili a in. Hot rolled deformed
(20-60) concrete (1569-1667) (4 and 5 mm) bars of low stressed
Soviet Union Round deformed steel are also used
4260-5100 Lightweight V-II 213,000-241,000 % and ghs in. for prestressing. All
(30-40) concrete (1471-1667) (9, 12, and 15 mm) longitudinal steel is
7-wire strand tensioned
240,000 and 's, '/s, and The in.
United States >5000 Normal ASTM A416 270,000 (9.5, 12.7 and 11 mm)
(35) concrete (1657 and 1863) 7-wire strand
Fig. 28. Horizontal testing of concrete pole Fig. 29. Structural testing of prestressed
for flexural capacity. concrete pole structure.

Fig. 30. Testing of pole structure.

so
FLECTION

DYNAMOMETER
2'

/f
ti

REACTION ' 4-WHEEL w


FRAMF DOLLY
Ui (FRJCTION) Li
J
O m
a
L/\
^n v

LOAD
REACTION
(SLIP AT POLE }— Il
W
J
47
QI
ik

-- REACTION
RSLIP)

CONCRETE SLAB

Fig. 31. Schematic of horizontal testing of concrete pole for flexural capacity.

. nnn rd i

__ a
LOAD
DYNRMOMETER

Fig. 32. Equipment used in testing pole structure.

PCI JOURNAUSepternber-October 1984 81


m
— OO
O O

I -SOFT
UNDER 100 FT LONG

ID

O O O O O O

1 15-25F1
LI5-a5FT
OVER IOO FT. LONG

a E^

CENTER OF E^
GRAVITY ^j'6 ^F^

UNDER 80 FT LONG OVER 80 FT LONG

Fig. 33. Truck loading data and handling lifting points of pole.

up to 90 percent of ultimate, and when porting and erecting. Some guidelines


the load is released, show no effect of for safe handling of prestressed concrete
the loading. poles are:
Structure testing is the simulation of 1. Always handle prestressed con-
the structure as it is to be used, loaded in crete poles with the major axis in
increments to its design loadings, in a the horizontal direction, with a
static condition (Figs. 29, 30, 32), to two-point balanced pickup.
check its structural strength and be- 2. While unloading from trucks, rail-
havior. road cars or waterway barges,
handle the poles gently. Under no
HANDLING circumstances should they be
TRANSPORTATION thrown onto a pile (Figs. 33 and
AND ERECTION 34).
3. Poles should he stacked level and
Although prestressed concrete poles supported so their own dead
are resilient and resist cracking, they re- weight will not cause them to sag,
quire special care in handling, trans- 4. While transporting by pole trailer

82
Fig. 34. Railroad transportation of poles.

^ i a

Fig. 35. Truck transportation of pole.

(Fig. 35), the poles should he held 6. H-frame structures should be as-
as rigid as possible to keep them sembled and lifted with the use of
from oscillating, which could cause a spreader bar. With structures
them to crack. The use of a strong- over 80 ft (24 m), a second pick
back is suggested, if necessary. point should be used to get the
5. When erecting single poles, it is pole butts off the ground when
suggested that they be rigged as lifting the structure to the vertical
shown in Figs. 36 and 37. position (Fig. 38).

PCI JOURNAUSeptember-October 1984 83


Fig. 36. Erection of a single pole structure.

Fig. 37. Erection of a German two section


bolted spliced structure.

Fig. 38. Erection of an H-frame structure.

84
Foundations for prestressed concrete
pole structures will vary because of
groundline moment capacity. For most
concrete pole applications, both self-
supporting and guyed poles, direct em-
bedment is all that is needed. When the
range of 500,000 ft-lbs (68,000 N.m)
groundline moment capacity is reached,
the foundation requirements, de-
pending on the reliability required of
the structure, should be considered.
Oversized holes may be excavated and
controlled backfill of crushed stone, soil
cement or concrete may be compacted
around the embedded section of the
pole.
When the concrete pole structure ex-
ceeds 1,000,000 ft-lbs (1,356,000 N.m) of
groundline moment capacity, the foun-
dation should he treated as a structural
Fig. 39a. Full automatic welding foundation and the capacity of the soil in
apparatus (Japanese), designing the foundation becomes an

PRESTRESSED
WIRE

WELDING
SEAT
PLATE

CONCRETE ANCHORING
REINFORCEMENT

Fig. 39b. Schematic of welded splice


(Japanese).

PCI JOURNAL`September-October 1984 85


J

Fig. 40a. Bolted splice (German). Fig. 40b. Schematic of bolted splice.

extremely important design factor. are assembled to the required pole


The tractor trailer unit may not be a length and post-tensioned or precast
suitable vehicle to transport the longer prestressed pole segments can be
poles in many areas which have narrow spliced in one of four ways. In Japan
acid winding roads. In such cases it may (Fig. 39) a thick steel plate is tensioned
be worthwhile to consider segmental to the ends of precast prestressed seg-
prestressed concrete poles. ments, and the pole is assembled by
welding the segments together to the
SEGMENTAL PRESTRESSED required length of the pole.
CONCRETE POLES In Germany (Fig. 40), bolts are cast in
the lower section of a precast pre-
Prestressed poles made of precast stressed segment. The upper segment
segments assembled at the site avoid has a galvanized steel section cast in
problems associated with transporting with blockouts which accept the bolts
the full length pole. These assemblies that are double-nutted to make the con-
under full scale testing have revealed no nection. This area is covered with a gal-
adverse effect on the ultimate strength vanized steel cover plate.
of the designed pole. Within the United States, two other
The assembly of segmental poles can splices have been developed and tested.
and has been done in two ways. Either The lap splice (Fig. 41) employs a gal-
prestressed or nonstressed precast units vanized steel section to be inserted into

86
Fig. 41 a. Slip joint splice.

the larger end of the form, The pre-


stressing strand is pulled through and
stressed to the form end plates. The
concrete is cast into the small end of the
tapered section. To develop the sec-
tion's strength in the prestressing strand
development areas, mild reinforcing
steel is added. The larger end of the ta-
pered steel section laps down over the
smaller end of the segment below at
least 1% times the diameter of the pole
sections at the splice. An air gap of 6 in.
(152 mm) is designed into the splice
between the plate in the splice unit and
the top of the lower segment. A keyway
is used to orient the segments correctly.
In the flange splice (Fig. 42), a steel
plate is prestressed to the splice ends of
the pole segments. The end plates are
then bolted together like a pipe joint to
develop the strength of the pole section. Fig. 41 b. Schematic of slip joint splice.

PCI JOURNAL/September-October 1984 87


t k-

Fig. 42a. Flange plate splice.

FUTURE USE AND


TECHNOLOGY
Most studies have indicated that the
first cost of prestressed concrete poles is
greater than timber, but less than steel,
in the range of sizes of prestressed con-
• • s
crete poles designed and used today. it
must be emphasized that numerous cir-
\s ue• . • .^ •
o - •
cumstances affect their economy, espe-
cially transportation and availability.
From the data collected, the facts indi-
cate that every country surveyed in the
report is using prestressed concrete
poles more and more frequently.
Future technology into higher
strength concrete with a 28-day strength
in the 10,000 to 12,000 psi (69 to 83
MPa) range may become standard as
efforts to produce stronger poles with
slender profile develop. Pole weights
may also decrease with the use of lighter Fig. 42b. Schematic of flange plate splice.
weight concrete. Sectionalized poles
will reduce shipping and handling
problems.
The development of concrete admix- doubtedly cause wood pole users to look
tures that provide concrete with accept- at concrete poles as an attractive alter-
able electrical insulating and mechani- native.
cal strength properties may open the Future technological developments in
way for innovative integrated design. concrete pole design, manufacturing,
The increasing market for wood prod- and costing will have a very definite im-
ucts may eventually eliminate wood pact on the future use of prestressed
from the pole marketplace; this will un- concrete poles.

88
SELECTED REFERENCES

1. Aheles, P. W., "Impact Resistance of 17. "Floodlighting Towers," ACI journal,


Prestressed Concrete Masts," 5th Con- March 1958.
gress, International Association for 18. George, Z., and Sethuraman, N., "Par-
Bridge & Structural Engineering, Lis- tially Prestressed Concrete Poles-A
bon, Portugal, 1957. New System of Manufacture Using High
2. Amin, ]. M., "Prestressed Concrete Fac- Strength Deformed Bars and Portable
tory at Vallabh Vidyanagar-Manufac- Stressing Beds," Indian Concrete Jour-
ture of Transmission Line Poles," Indian nal, October 1975.
Concrete Journal, May 1959, 19. George, Z., Swaminathan, K. V., Dayarat-
3. Axtell, H. D., "Concrete Pole Met Cost, ram, P-, and Salvi, K. G., 'Prestressed
Appearance Requirements," Electric Concrete Poles-State of the Art," Inter-
Light dr Power, April 1969. national Seminar on Prestressed Con-
4. Axtell, H. D., "Concrete Transmission crete Poles, Pipes & Pressure Vessels,
Towers Blend With Rugged Scenery," Madras, India, 1972.
Electrical World, September 2, 1963. 20. "Germany's Centrifugal Concrete
5. Axteli, H. D., "Prestressed Concrete Poles," Concrete, November 1955,
H-Frame Transmission Towers," E & 0 21. Ghosh, R. J., and Jenkins, G. A., "Load
Section NWPPA, Tacoma, Washington, Testing of Prestressed Concrete Trans-
1963. mission Pole and Its Concrete Footing,"
6. "Bright Prospects for Concrete Light Ontario Hydra Research Quarterly, First
Poles," Concrete Products, November Quarter, 1977.
1966. 22. "Grandview No Longer a Tunnel," The
7. "Concrete Poles Are Placed in Concrete American City, November 1960.
Cylinders to Build Line Over Salt 23. Grzezorzewski, W., "Prestressed Con-
Water," Transmission and Distribution, crete Poles in Poland," FIP Symposium
October 1967. on Mass-Produced Prestressed Precast
8. "Concrete Poles Require No Make-Up," Elements, Madrid, June 1968.
The American City, March 1957. 24. "Interest in Concrete Poles Increases,"
9. Commack, H. W., "Notes on Prestressed Electrical World, V. 184, No. 12, Decem-
Poles," New Zealand Enginee ri ng, June ber 15, 1975.
15, 1952. 25. Ironman, R., "Spinning Molds Form Pre-
10.Cormack, H. W., "'Precast Concrete for stressed Concrete Lamp Standards,"
Prestressing With Special Reference to Concrete Products, June 1958.
Concrete Poles," New Zealand Engi- 26. Ismael, N. F., "Concrete Pole Test
neering, February 15, 1953. Foundation Instrumentation and Test-
11. "Costa Rica Has Tallest Precast Concrete ing," Stress-Crete Ltd., Ontario Hydro
Towers," Civil Engineering, March Research Division, Report No. 740-624-
1961. 199-3303, January 6, 1976.
12. Crisp, C. F. C., "A Survey of Concrete 27. King, C. F., "Vepco's 230 kV Single Cir-
Transmission Line Poles," Construction cuit Line Using Spliced Concrete Poles,"
Review, December 1955, Australia. Virginia Electric and Power Company,
13. "Design of Reinforced Concrete Trans- Richmond, Virginia.
mission Line Pole," Indian Concrete 28. MacCarthy, H. P., "Concrete Pole De-
Journal, December 15, 1974. sign & Applications," Edison Electric
14. "Detailed Static Calculation of Pre- Institute, Transmission and Distribution
stressed Concrete Poles," Betonstein- Committee, Seattle, Washington, Octo-
zeitung, June 1964, German, ber 3-4, 1974.
15. Dmitriex, S., "General Report on Pre- 29. Mhatre, R. P., "Prestressed Concrete
stressed Concrete Poles," FIP Sympo- Poles for Power Transmission Lines,"
sium on Mass-Produced Prestressed Pre- Indian Concrete Journal, August 1959.
cast Elements, Madrid, June 1968- 30. "Concrete Poles for 110 kV Aerial Power
16. "Prestressed Concrete Pole Transmis- Transmission Lines," Pfleiderer Con-
sion," Eugene Water and Electric Board, sulting CMBH, Neumarkt/OPF.
February 10, 1970. 31. Pilsbury, W. L., "Prestressed Concrete

PCI JOURNAL/September-October 1984 89


Hurricane-Proofs 230 kV Line," Electri- 43. Rosam, M. E., "Hurricane Rip At Key
cal World, July 1, 1963. West New 69 kV Line Overhead and
32. "Precast Concrete Lighting Columns," Water," Electrical World, November 17,
Concrete Building & Concrete Products, 1963.
V. 28, No. 1, January 1953. 44. Ruckhaus, F., "Prestressed Concrete
33. "Prestressed Concrete Carriers p ower of Transmission Line Structure,"Jou rn al of
the Future," PCltems, V. 7, No, 8, August the Power Division, Proceedings,
1961. American Society of Civil Engineers, V.
34. "Prestressed Concrete Poles Need No 94, No, P-01, May 1968.
Footing," Electrical World, January 19, 45. Schupack, M., and McDonald, A., "Expe-
1970, p. 37. rienced Transmission Tower of Pre-
35. "Prestressed Concrete Poles Prove Prac- stressed Concrete," Civil Engineering,
tical," Electrical World, V. 174, No, 11, August 1961.
December 1970. 46. Schupack, M., "Design of an Extra-High
36. "P.S.I. Test Concrete Pole, Design Voltage Transmission Tower 100 Feet
Limits Exceeded," Electric Light & High," PCI JOURNAL, V. 7, No. 1, Feb-
Power, January 1979. ruary 1962, pp. 32-46.
37. Price, B., "Prestressed Concrete—It's 47. "Sectional Concrete Pole Design Eases
Role in Beautility," Utilities Appearance T-Line Construction Problems," Electric
Committee Meeting, Phoenix, Arizona, Light & Power, September 1978.
January 12, 1967. 48. "Simplified Method for Static Calcula-
38. Rodgers, T. E., Jr., "Developing Pre- tion of Prestressed Concrete Poles," Be-
stressed Concrete Poles," Electrical tonsteinzeitung, February 1964 (in Ger-
South, February 1971. man).
39. Rodgers, T. E., Jr., "A Utility's Devel- 49. "Spun Concrete Poles to be Made by St.
opment and Use of Prestressed Concrete Louis Finn," Traffic Engineering, March
Poles," Southeastern Electric Exchange, 1959.
Engineering & Operations Division, 50. "Spun Lighting Columns," Concrete
Transmission Section, Hollywood, Building and Concrete P roducts, May
Florida, October 16, 1970. Also pub- 1959.
lished in PC! JOURNAL, V. 17, No 3, 51. "110 kV Transmission Poles," Construc-
May-June 1972, pp. 8-13. tional Review, V. 45, No. 2, May 1972.
40. Rodgers, T. E., Jr., "Vepco's Design and 52. Vondrasek, Jaroslav, "Production of Pre-
Use of Prestressed Concrete Poles," stressed Concrete Poles," Inzenyrska
Canadian Electrical Association, Trans- 5tavby, 1974.
mission Sections, Winnepeg, Manitoba, 53. Woodson, L. V., and Whitlow, J. C.,
Canada, September 24, 1974; South- "Poles Designed to Provide Clearance
eastern Electrical Engineering & Oper- for Conversion," Electrical World, De-
ation Division, Transmission Sections, cember 19, 1966-
New Orleans, Louisiana, April 26, 1976; 54. Woodson, L. V., "Spun Concrete Poles
Pennsylvania Electric Association, Show Favorable T&D Potential,"
Transmission & Distribution Committee, Transmission & Distribution, July 1968.
Engineering Section, Pittsburgh, 55. Wright, C. E., ` Prestressed Concrete
Pennsylvania, January 26, 1977. Poles," Concrete Products, September
41. Rodgers, T. E., Jr., Anderson, W. C., and 1955.
Change, D. R., "Guide fnr Design and 56. PCI Committee on Prestressed Concrete
Specifications for Concrete. Pole Struc- Poles, "Guide Specification for Pre-
tures, IEEE Committee Report, Trans- stressed Concrete Poles," PCI JOUR-
action Paper, V. PAS-94, No. 4, July- NAL, V. 27, No. 3, May-June 1982, pp.
August 1975. 18-29.
42. Rodgers, T. E., Jr., and Riley, D. L., 57. PCI Committee on Prestressed Concrete
"Prestressed and Post-Tensioned Con- Poles, "Guide Design for Prestressed
crete Structures," Transmission & Dis- Concrete Poles," PCI JOURNAL, V. 28,
tribution, December 1973. No. 3, May-June 1983, pp. 22-87.

•d
SPECIFICATIONS/ STANDARDS
1. BPA Specification for PrestressedConcrete September 1974.
Transmission Structures, Bonneville 10. JIS A5309-1977, Pretensioned and Re-
Power Association, December 1972. inforced Spun Concrete Poles, Japanese
2. BS 607, 1960 Specification for Concrete Industrial Standard, 1971.
Poles for Electrical Transmission and 11. National Electrical Safety Code, ANSI
Traction Systems, British Standard In- C2, 1977 Edition.
stitution, 1960. 12. NZS 1054-1966, Concrete Poles for
3. CSA Standard A14-M-Concrete Poles, Electrical Transmission, Standards As-
Third Draft Proposed, Canadian Stan- sociation of New Zealand, November
dards Association, May 1978, 1966.
4. DIN 4228, Prestressed Concrete Mast, 13. prEN 40, Draft 2, Lighting Columns,
Regulation for Design and Manufacture, Special Requirements for Reinforced
Lerman Norms, October 1964. and Prestressed Concrete Lighting
5. EIA-RS-222-C, Electronic Industries As- Poles, CEN European Committee for
sociation Standard, March 1960. Standardization, Central Secretariat: Rue
6. IS: 1678-1978, Indian Standard Specifi- Brederode, 2, B-1000 Brussels, Part 9,
cation for Prestressed Concrete Poles for Edition 1, June 1979.
Overhead Power, Traction and Tele- 14. Standard Specification for Structural
communication Lines, Indian Standards Supports for Highway Signs, Luminaires
Institution, New Delhi, August 1979. and Traffic Signals, AASHTO Subcom-
7. IS: 2193-1962, Indian Standard Specifi- mittee on Bridges and Structures, 1975.
cation for Prestressed Concrete Street 15. 8-2101, Specification for Prestressed
Lighting Columns, Indian Standards In- Concrete Poles, Standards Overhead
stitution, New Delhi, January 1963. Transmission lines, Florida Power &
8. IS: 2905-1966, Indian Standard Methods Light Co., November 1973.
of Test for Concrete Poles for Overhead 16. PCI Committee on Prestressed Concrete
Power and Telecommunication Lines, Poles, "Guide Specification for Pre-
Indian Standards institution, New Delhi, stressed Concrete Poles," PCI JOUR-
June, 1966. NAL, V. 27, No. 3, May-June 1982, pp.
9. IS: 7321-1974, Indian Standard, Code of 18-29.
Practice for Selection, Handling and 17. PCI Committee on Prestressed Concrete
Erection of Concrete Poles for Overhead Poles, "Guide Design for Prestressed
Power and Telecommunication Lines, Concrete Poles," PCI JOURNAL, V. 28,
Indian Standard Institution, New Delhi, No. 3, May-June 1983, pp. 22-87.

NOTE: Discussion of this paper is invited. Please submit


your comments to PCI Headquarters by May 1, 1985.

PCI JOURNAUSepternber-October 1984 91


COMPANY BROCHURES (AMERICAN-CANADIAN)
1. American Concrete Lighting Poles & sion, 1000 Alberta Place, 1520-4th
Stress-Spun Concrete Lighting Stan- Street S.W., Calgary, Alberta T2R 1H5,
dards, Union Metal Manufacturing Co., Canada.
P.O. Box 308, East Stroudsburg, Penn- 7. Prestressed Concrete Poles, American
sylvania 18301. Precast Concrete, Inc., 1030 South Kitley
2. Centrifugally Cast, Prestressed Concrete Avenue, Indianapolis, Indiana 46203.
Poles, Bayshore Concrete Products Cor- 8. Prestressed Concrete Poles, Power Span
poration, P.O. Box 230, Cape Charles, Inc., P.O. Box 1056, Hayfield, Minnesota
Virginia 23310. 55940.
3. Concrete Lighting Poles, Ameron, Pole 9. Prestressed Concrete Poles, The Cretex
Products Division, P.O. Box 755, 1020 Companies, Inc., 311 Lowell Avenue,
"B" Street, Fillmore, California 93015. Elk River, Minnesota55330.
4. Concrete Poles, Sherman Utility Struc- 10. Prestressed Concrete Products, Concrete
tures, Inc., 3735 32nd Avenue, Tusca- Poles, Dura-Stress Inc., P.O. Box 779,
loosa, Alabama 35406, Leesburg, Florida 32748.
5. Inficrete Poles, Barratt Spun Concrete 11. Prestressed Concrete, Transmission
Poles Ltd., P.O. Box 372, 4536 Mont- Poles, REM-Co Products, Inc., P.O. Box
rose Road, Niagara Falls, Canada L2E 7, Hayfield, Minnesota 55940.
6T8. 12. Prestressed Concrete Transmission
6. Precast Prestressed Concrete Poles, Structures, Contran, P.O. Box H, Osseo,
Genstar Structures Limited, Pole Divi- Minnesota 55369.

COMPANY BROCHURES (EUROPEAN)


1. Beleuchtungsrnaste, SACAC, Buro, pon Concrete Industries Co., Ltd.,
Zurich, Switzerland. Tokyo, Japan.
2. Beton, N. V. Cobefa Zolder, Brussels, 11. Normalmaste fiir 50-kV-Leitungen,
Belgium. SACAC, Buro, Zurich, Switzerland,
3. Centrifugal Concrete Machinery, Cen- 12. Pfleiderer Consulting GMBH, New-
tricon, Bonn, West Germany. marketlOPF, West Germany.
4. Concrete Utilities Limited, Ware, 13. Poteauz d'Eclairage Public, Comit6
Herts, England, Electrotechnique Beige, Brussels, Bel-
5. Dainichi Concrete Industry Co., Ltd., gium.
Nagoya, Japan. 14a- Prestressed Concrete Transmission
6- Di' positif de Seeurite le Bag, Cram SA, Poles. Stanton & Stave ley, British Steel
Villeneuve, France. Corp., Nottingham, England.
7. L'Eclairage du Reseau, Routier Beige, 14b. Prestressed Spun Concrete Lighting
Catalogue Pernament Industrie du Columns, Stanton & Staveley, British
Beton. Steel Corp., Nottingham, England.
8. Ligne Normalisee 132 kV, Liste des 15. Reinforced Concrete Poles, Stefan
Mats ET, Calculs Statiques, Gram SA, Westberg, MSc, VAXJO, Sweden.
Villeneuve, France. 16. SA des BPtons Centrifuges Lenzbourg,
9. Liste des Adherents, Federation Fran- Cram SA, Villeneuve, France.
caise de l'Industrie du Beton, France. 17. Spun Reinforced Concrete, Fratelli
10. NC Poles, Spun Concrete Poles, Nip- Carrara S.N.C., Vicenza, Italy.

92
APPENDIX
PRESTRESSED CONCRETE POLE APPLICATIONS

Fig. A1. Flag pole. Fig. A2. Area lighting.

Fig. A3. Area lighting.

PCI JO1J NALJSeptember-October 1984 93


Fig. A4. Area lighting—Tennis court.

Fig. A5. Area lighting—Baseball field.

94
Fig. A6. High rise area lighting — Fig. A7. High rise area lighting —
Parking lot. Football field.

Fig. A8. Power distribution and street Fig. A9. Power distribution and street
lighting. lighting.

PCI JOURNAL/September-October 1984 95


Fig. A10. Power distribution and street Fig. Al1. Power distribution and street
lighting. lighting.

Fig. Al2. Power transmission with Fig. A13. Power transmission with
distribution underbuiId and area lighting, distribution underbuild.

96
II I!

Fig. A14. European power transmission. Fig. A15. European power transmission.

Fig. Al 6. Close-up of European power transmission.

PC JOURNAL/September-October 1984 97
Fig. A17. European power transmission.

Fig. Al B. Power transmission. Fig. A19. Power transmission.

98
A ^ ^

Fig. A20. Power transmission. Fig. A21. Power transmission.

Fig. A22. Power transmission.

PCI JOURNAL/September-October 1984 99


r

_
Fig. A23. Power transmission. Fig. A24. Power transmission—Switch
structures.

Fig. A26. Power transmission—Switch


Fig. A25. Power transmission. structures.
Fig. A27. Power overhead transmission to underground transmission.

Fig. A28. Power substation structures.

PCI JOURNAL/September-October 1984 101


Fig. A29. Power substation structures.

Fig. A30. Power substation structures, Fig. A31. Power substation structures.

102
F

Fig. A32. Communication structures -


Microwaves and area lighting.

Fig. A33. Communication structures — Microwaves and area lighting_

PCI JOURIVAL)September-October 1984 103

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