Thermal Powertech Corporation India Ltd

Key Achievements

• Keller’s expertise in performing complex and large foundation works (installing 3,000 bored piles) ensured the project delivery within a tight time frame of 10 months.
• Proper planning and execution helped in maintaining the momentum of the project.
• In spite the challenging site conditions, Keller maintained stringent safety and quality standards.

The Project

TPCIL was developing 2x660 MW Thermal Power Plant at Krishnapatnam, Andhra Pradesh. The Power Plant comprised of structures such as boilers, chimney, turbo generators, ESP cooling tower, CHP, AHP, etc. All these heavy structures were designed to be built on pile foundations. Keller was commissioned by the main contractor to perform heavy foundation works using bored piling technique  and to perform civil interface works for the aforementioned plant structures.

The Challenge

The geology of site consists of silty clay predominantly with alternative layers of loose fine sandy soil which is highly collapsible in nature while boring. The heavy structures of the proposed power plant required deep foundations in the form of pile foundations. The presence of such alternate layers of sand and soft clays' has posed challenges to the design and construction of the deep pile foundations. 

The Solution

The overall works involved installing about 3,000 numbers of 0.76 meter diameter bored piles. Majority of the piles were terminated within 35 to 40 meters below the existing ground level (EGL) however for few structures, piles were as deep as 60 meters below the EGL. To achieve a continuous supply of 50,000m3 concrete within a tight project schedule, Keller erected and operated a dedicated onsite batching plant.

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Project Facts