PMW CONCRETE INDUSTRIES

SDN. BHD.

PCI

SPECIFICATION OF
PRESTRESSED SPUN CONCRETE POLE
FOR
9.0m - 14 - 2.0kN
(Distribution Poles)

LOT 133077, JALAN LAHAT,

BUKIT MERAH INDUSTRIAL ESTATE,
31500 LAHAT,
PERAK, MALAYSIA
TEL: 605-321-9022
FAX: 605-321-8070
 SPECIFICATION OF PRESTRESSED SPUN CONCRETE POLE
FOR
9.0m - 14 - 2.0kN
(Distribution Poles)
Manufactured by
PMW CONCRETE INDUSTRIES SDN. BHD.
_______________________________________________________________________________

1. DESIGN CONDITIONS OF PC POLE

1.1 The design of PC pole is made according to Japanese Industrial Standard (J.I.S)
A5309: 1992 and specification of PMW CONCRETE INDUSTRIES SDN. BHD.

1.2 In this design, 8 non-tension wires of 6.0mm in diameter are allocated, beside 6
PC wires of 5.0 mm in diameter.

1.3 The said allocation of non-tension wires which are welded to the spiral wires
having 2.7mm in diameter are considered as an effective method to protect PC
pole from the damages occurred by impact of a vehicle colliding.

2. DIMENSIONS OF PC POLE

2.1 The shape and dimension of PC pole designed by PMW CONCRETE

INDUSTRIES SDN. BHD. which meets TNB's specification is shown on
Table- 1.

Table- 1

Pole length Top Wall Bottom Taper Embedded Design

(m) diameter thickness diameter length weight
(mm) (mm) (mm) (m) (kg)
9.0 140 33 260 1/75 1.50 410
3. DESIGN LOAD AND DESIGN MOMENT OF PC POLE

Design Load and Design Moment of PC pole are shown on Table – 2 & 3

a) Table – 2

Pole length Pcr Pd Pmu Pu Pcr/Pmu Pu/Pm

(m) (kgf) (kgf) (kgf) (kgf) u

9.0 158 200 400 450 0.395 1.125

Pcr : Cracking Load

Pd : Design Load
Pmu : Minimum Ultimate Load
Pu : Ultimate Load (Breaking Load)

b) Table – 3

Pole length Mcr Md Mu Mmut Mcr/Mmut Mu/Mmut

(m) (tf.m) (tf.m) (tf.m) (tf.m)
9.0 1.086 1.378 3.100 2.756 0.394 1.125

Mcr : Cracking Moment

Md : Design Moment
Mu : Ultimate Moment
Mmut : Minimum Ultimate Transverse Moment (Md x 2.0)

Note : 1. Design Transverse Load is 2.0kN

2. The Load at failure shall exceed 2.0 times of Design Transverse Load.
3. Calculation was made based on the under mentioned figures.

Concrete δcu = 500kg/cm2 (Based on cylinder test piece)

δbu = 60kg/cm2 (Based on cylinder test piece)
EC = 400,000kg/cm2

PC wire Dia = Ø 5.0 mm

δpy = 14,000kg/cm2
δpu = 16,000kg/cm2

Reinforcing wire & Spiral wire

Reinforcing wire Spiral wire
Dia = Ø 6.0mm ; Ø 2.7mm
δpy = 4,000kg/cm2 ; 2,100kg/cm2
δpu = 4,000kg/cm2
δcu = specified compressive strength of concrete
δbu = specified flexural tensile strength of concrete
Ec = modulus of elasticity of concrete
δpy = specified yield strength prestressing steel
δpu = specified ultimate strength of prestressing steel
 The drawing of structure of pole and the moment diagram is shown in Bending
Moment Diagram (Drawing No: PCI/PSCP-BMD/P-303-03-07) and the drawing of
allotment of structural members, such as PC wires, reinforcing wires and spiral wires
is shown in Pole Drawing (Drawing No: PCI/PSCP-PD/P-303-01-07) and Structural
Drawing (Drawing No: PCI/PSCP-SD/D-203-02-07).

4. RAW MATERIALS OF PC POLE

Raw materials required of PC pole are shown on Table -3.

Table -3

Pole length PC wire Reinforcing wire Spiral wire Concrete

(m) (kg) (kg) (kg) (m3)

6-Ø 5.0 8-Ø 6.0 Ø 2.7 0.1529

9.0
11.988 9.324 1.306

Above figures are based on the design value.

5. REQUIRED QUALITY OF RAW MATERIALS

5.1 Cement

5.1.1 The deteriorated cement shall not be used.

5.1.2 The cement shall conform to the standard of the ordinary Portland
Cement specified in JIS R 5210 or MS 522.

5.2 Fine Aggregate

5.2.1 The fine aggregate shall be clean, hard and durable and shall not include
to harmful extent dust, mud, organic sub-stances, clay lumps, stone,
mica particles and salt.

5.2.2 The fine aggregate shall have a proper mix of small and large sizes, and
the size of the grains, the fineness modulus, the quantity of the mud, the
unit weight, the organic impurities and the water absorption shall
conform to the standard as shown in Table-4.

Table-4

Item Maximum Fine Quantity Unit Organic Specific Water

Grain modulus of mud weight impurities gravity Absorption
diameter
Fine Less than 2.05 ~ 3.30 Less than Greater Higher Greater Less 1.5%
aggregate 5mm 3% than 1500 than than 2.55
kg/cm2 standard
color

5.3 Coarse Aggregate

5.3.1 The coarse aggregate shall be clean, hard and durable and shall not
include to a harmful extent dust, mud, organic substances, thin pieces,
slender pieces of stone, clay lumps, rocks, soft stows and salt.

5.3.2 The coarse aggregate shall have a proper mix of small and large size.

5.3.3 The maximum size, the fineness modulus, the quantity of mud the unit
weight, the specific gravity and the water absorption shall conform to
the standard as shown - Table 5.

Table 5

Item Max size Fineness Quantity Unit Organic Water

modulus of mud weight impurities absorption
Coarse 13mm 6.30 ~ 6.90 No more No less No less No more
aggregate than than 1500 than than
1.50% kg/cm2 2.55 1.50%
5.4 Admixture

5.4.1 The admixture to use shall be SP 2000 GL or its equivalent, compliance to

MS 922.

5.4.2 The color, the pH value, the specific gravity and the purity of the solute
admixture shall be conform to standard specification and the content of
calcium chloride shall be so limited as not to give ill effect to the
reinforced steel material.

5.5 Steel Materials

5.5.1 The tension steel wire shall conform to JIS G 3536.

5.5.2 The non-tension wire such as the reinforcing wire and spiral wire shall
conform to JIS G 3532.

5.6 Insulating Tube for Earth Wire Inlet & Outlet

5.6.1 The shape dimensions and quality shall be as shown in Accessories

(Drawing No: PCI/PSCP-A/D-203-04-07)

5.7 Through Hole

5.7.1 The sockets shall be made of brass

5.7.2 The shape dimensions and quality shall be as shown in Accessories

(Drawing No: PCI/PSCP-A/D-203-04-07)

5.8 Pole Marking

5.8.1 The shape dimensions and quality shall be as shown in Pole Marking
(Drawing No: PCI/PSCP-PM/D-203-05-07)

5.9 Earth Wire

5.9.1 The galvanized earth wire of size 7/18 SWG shall be provide inside the
pole. It shall be coiled inside the pole. It shall be coiled inside the pole
and shall conveniently be pulled out through the earth wire outlet.

5.9.2 The length and position of the earth wire provided in the spun pole shall
be as shown in Earth Wire ((Drawing No: PCI/PSCP/5520-08).
6. MANUFACTURE:

General
A quality system of manufacturing complying with MS ISO 9002 must be established.

6.1 PC Steel and Reinforcement

6.1.1 PC Steel members and reinforcement steel bars shall be cut to correctly
coincide with the shapes and dimensions specified in the drawing.

6.1.2 The PC member and reinforcement shall be arranged so that they are
uniformly distributed in the cross-section of the concrete pole.

6.1.3 The spacing of PC Steel and reinforcement shall not be smaller than 5/4
of the maximum size of the coarse aggregate or the diameter of the
tension wire.

Where accessories are attached, the spacing shall be large enough not to
harm the quality of the pole.

6.1.4 Additional bars shall be arranged spirally outside the PC Steel and the
longitudinal reinforcement. This spiral wire shall have a diameter not
smaller than 2.7 mm and the pitch shall not be more than 150 mm.

6.1.5 All steel reinforcement shall have a concrete cover of not less than 9 mm
without any adjustment of PC wire or reinforcement bar.

6.1.6 The PC Steel members shall not be jointed by any method. Welding
process strictly shall not be use at parts of PC Steel.

6.1.7 Manual method to form cage of spiral wire to PC Steel shall not be used.

6.1.8 The spiral type additional bar is jointed with the longitudinal
reinforcement by welding, it shall be ensured that the mechanical
properties of these steel after welding are not lowered due to welding.

6.2 Moulding

6.2.1 Mould used shall be sufficiently rigid in order to withstand forces.

Mould also shall be in single unit and not knock down type.

6.2.2 The PC Steel and reinforcement steel bars shall arrange rigidly in
accordance with 1.2 and 1.3 before placing (by injection method) the
concrete. The PC steel shall be tensioned in advanced before the
compaction process.
6.3 Pre-tensioning of Wires

6.3.1 The PC Steel shall be arranged at a proper position and then stretched
and firmly fixed at both ends so that the tension is not reduced until the
concrete is sufficiently cured.

6.3.2 All the 6 PC Steel shall be stretched together at the same time. The
method of stretching PC Steel one by one shall not be used.

6.3.3 The PC wire will then be cut to exert the stress or the concrete.

6.3.4 The pretension shall be introduced gradually.

6.3.5 The initial tensile force shall be as large as necessary to obtain the
required pretension but shall not exceed 70% of the tensile load of the
PC steel and 80% of the yield point load.

6.3.6 The compressive strength of concrete at the time when pre-stress is

applied (i.e. when PC wires are cut) shall be more than 24.5 N/mm2. The
test method is specified in JIS A 1136.

6.4 Concrete

6.4.1 The concrete shall be thoroughly mixed in a mixer and shall be used
immediately to prevent concrete setting which causes uneven
distribution concrete and honey comb.

6.4.2 Open feeding (manual) method for mould concreting shall not be used.

6.4.3 The quality of the concrete shall be such that the compressive strength at
the age of 28 days is not lower than 49 N/mm2. Test method specified is
JIS A 1132 and JIS A 1108 shall be followed.

6.4.4. The quantitative measurement of the materials used for concrete shall be
by mass. However, water and admixture may be measured by volume.

6.4.5 Cross sectional area of pole shall be even through the whole length of
pole. Uneven cross sectional area or solid pole especially at top pole
shall be rejected.

6.4.6 3 samples of cylinder test for every batch of concrete mixture shall be
provided for concrete test.
 6.5 Spinning

6.5.1 Spinning process shall be take place immediately after concreting.

6.5.2 The rpm speed and time of spinning process shall be sufficient to form
even distribution of concrete compactness through the whole length of
pole.

6.6 Curing

6.6.1 The concrete poles shall be cured by steam curing not less than 5 1/4
hours with maximum temperature 75°C are recommended after 2 hrs
curing.

6.6.1 Minimum time of curing for maturity at least 10 days before the pole can
be tested or delivered to site.

7. QUALITY

7.1 Appearance

The poles shall be dense and free from defects such as cracks and voids and the
surface must be smooth.

7.2 Sampling Test

Sampling test shall be carried out by the manufacturer on sample of products in

the finished state. The sampling test shall be made on the pole are :-

i. Bending Strength Test

ii. Breaking Test

7.2.1 Bending Strength Test

The bending strength test shall be conducted on three poles sampled

from a batch of 1000 poles or part thereof.

This test shall be carried out in accordance with JIS A 5309. When the
design transerve load of 200 kg is applied, crack exceeding 0.25mm in
width shall not appear, when the design load is removed, there shall be
no remaining cracks exceeding 0.05mm in width.
 7.2.2 Breaking Test

This test shall be carried out in accordance with JIS A 5309: 1992.

The load is applied to the pole in one of the two loading directions until
the pole is broken. Take the maximum load shown by the load meter
during the period to the breakage as the breaking load of the pole.

This breaking load shall be more than twice the design load.

7.3 Tolerances

The dimensional, weight and wall thickness tolerances shall be as shown as

below (caps and bottom covers shall not be included in the dimension )

Classification Tolerances (mm)

Outside diameters ±4
Length ± 25
Weight ± 15%
Wall thickness - 1%+30%

7.4 Type Test

The prestressed spun concrete pole shall comply the types tests in accordance
with procedures established by JIS A 5309 (or the corresponding clauses in the
earlier versions as long as the old clauses are not superceded)

In the event that modifications to the design of the product are made which in
the opinion of TNB that it will affect the performance of the product, the
relevant type tests shall be repeated at the expense of the manufacturer.

7.5 Routine Test

Routine test shall be carried out by the manufacturer on all products in the
finished state or, where appropriates, during the manufacturing processes in
accordance to JIS A 5309.

i. Visual and dimensional check

ii. Marking
 7.5.1 Visual and Dimensional Check

i. Inspection of the appearance, shape, dimension and tolerance shall be

performed on all poles.

ii. Inspection of the cover shall be performed with respect to the pole which
have subjected to the breaking tests

iii. The concrete pole shall be dense in quality and free from harmful flaws
and cracks.

iv. Inspection on the wire arrangement shall be performed on all the poles.

v. Inspection on the pole cap (upper cap and lower cap) shall be performed
on all the poles.

vi. All the pole shall comply with the specification with respect to the visual
and dimensional check.

7.5.2 Marking

Inspection on the marking shall be performed on all poles. All marking

shall comply with to the standard as stipulated in subsection 9.1 as stated
in this specification.

8. INSPECTION & ACCEPTANCE CRITERIA

8.1 Inspection shall be made based on Total Quality System Standard which is
include raw material, method of manufacturing processes and finish product.

8.2 Inspection of finish product for acceptance will only carried out if Inspector
satisfied with the total Quality System Standard.

8.3 Inspection of finish product shall be made on appearance, shape, dimension,

concrete cover and bending strength.

8.4 The whole batch of poles is accepted if all the requirements are full filled.

8.5 The whole batch of poles is rejected if the requirements are not full filled.
8.6 Acceptance Test

For each contract, a schedule for the implemention of acceptance testing shall
be agreed between the manufacturer and customer in order that acceptance
testing may be carried out on a regular basis. All routine test results carried
out by manufacturer shall be made available for inspection during acceptance
testing. On the passing of the tests, security labels shall be affixed to each box
in the lot in order to signify approval at factory.

The acceptance test to be carried out by the manufacturer and witnessed by a

reprensentative of customer shall consist of all the test listed under routine tests
and sampling test.

The representative of customer shall randomly select three units of prestressed

spun concrete pole from batch of 1000 poles or part thereof.

The bending strength test shall be conducted on all the three poles sampled
from the above batch. If any sample fails in any of the test, two further samples
shall be taken from the same batch and submitted to the same tests or tests in
which the original sample failed. If both additional samples pass the tests, all
the products in the batch from which they were taken shall be regarded as
complying of this standard. If either of the additional samples fails, the batch
from which they were taken shall be regarded as failing to comply

The breaking test shall be conducted on one of the three poles in the bending
strength test. If the sample fails in the tests, two further samples shall be taken
from pole used in the bending strength test and submitted to the same test or
the test in which the original sample failed. If both additional samples pass the
test, all the products in the batch from which they were taken shall be regarded
as complying with the requirement of this standard. If either of the additional
samples fails, the batch from which there were taken shall be regarded as
failing to comply.
9. MARKINGS:

9.1 Each pole must be marked clearly with the following information:

(i) Customer name or logo.

(ii) Name of abbreviation of manufacturer.

(iii) Danger Sign.

(iv) Dimension and design strength.

(v) Reference standard.

(vi) Pole serial number.

(vii) Date of manufacture.

(viii) Position of centre of gravity.

(ix) Line voltage level.

(x) Embedded length.

(xi) TNB contract number.

Except for item (ix), the marking should be made at approximately 3.0m
from the bottom end.
10. LIST OF APPLICABLE STANDARD

MS 522)
BS 12) Portland cement.

MS 922 Admixture.

JIS A 5309: 1992 Prestressed spun concrete pole.

JIS A 1108 Method of test for compressive strength of concrete.

JIS A 1132 Method of making and curing concrete specimens.

JIS A 1136 Method of test for compressive strength of spun concrete.

JIS G 3532 Low carbon steel wire.

JIS G 3536 Uncoated stress - relieved steel wire and stand for prestressed
concrete.

******** END OF SPECIFICATION ********