Record Concreting of over 6,50,000 m3 by Patel Engineering Ltd.
Two Schwing Stetter Concrete Batching and Mixing plants–Models HN 3.0 (120 m3/hr) and one HN 4.0 (160 m3/hr) were installed aggregating to 400 m3/hr batching capacity. The plants had twin shaft mixers and the control system was Stetter MCI 300 system.
Ghatghar Pumped Storage Scheme is a hydropower generation project constructed by Irrigation Department Govt. of Maharashtra. Total 250 MW power will be produced from this hydro power plant. Three dams Saddle Dam No. 1, 2, and Upper Dam, build up the upper reservoir. Lower dam builds up the lower reservoir. Water conductor system consists of inclined underground pressure shaft and the underground powerhouse, which has two units of 125 MW turbines. These turbines act as reversible pumps. In nonpeak hours the water from the Lower Dam reservoir, which will be filled with water, and stored after power generation, will be pumped back to Upper Reservoir. Saddle Dam No. 1, Upper Dam and Lower Dam are built in Roller Compacted Concrete.
Principal designers of the project are EPDC, Japan, in association with Tata Consulting Engineers, India and Malcolm Dunstan and Associates (MD&A) U.K.
The project was awarded in November 2001 to Patel Engineering, Mumbai, India’s one of the oldest and experienced general contractors. ASI RCC (ASI) of Buena Vista, Colorado, USA, a well-established international contractor is a wholly owned subsidiary of Patel Engineering and they provided technical expertise for the construction of the RCC Dams.
RCC WorkDifferent methods of delivery of RCC into the dam body were studied and finally best option was selected and the entire site layout was finalized. As per the layout all the equipment were erected. It was decided to place RCC in two halves so as to avoid un-planned cold joints.
The RCC delivery system comprised of belt conveyor delivering 400 m3 /hr. Four waterchilling plants were installed for chilled water supply to three batching plants and ice plants. Two crushing and screening plants for aggregates production were installed. One 250 TPH crushing plant and 100 TPH were deployed. Two 120 TPH and one 150 TPH ice flake plant were commissioned, having automatic ice handling system. Equipment for RCC placement on dam body comprised of 20-ton dump trucks for collecting RCC from Belt conveyor and truck unloader, D-5 dozer for spreading RCC, 10-ton vibratory roller for compaction. Cranes for form erection and many other minor equipment like high frequency vibrators, small roller etc.