Gersteinwerk power station, Werne

RWE recently undertook to modernise a gas turbine and turbine deck at the Gersteinwerk power station in Werne. A new foundation for the turbine block was required to successfully disperse expected additional loads. PORR Spezialtiefbau Düsseldorf branch was contracted to manufacture 36 micropiles for this project.

The existing structure was built on a foundation of Frankipfahl piles. The basement location of the foundation works required the application of compound micropiles measuring 160mm in diameter, 50mm-diameter supporting elements and a drilling depth of up to 18.6m. With limited clearance – in some places just 2.05m of headroom – and generally restricted space conditions, this construction scheme presented significant logistical challenges for the team. Our Düsseldorf-based construction team used two different specialist pieces of equipment to complete this project. Where vertical clearance was particularly limited, the team used an HBR202-E drill with a short carriage; in other areas, the KR704-2E drill was used, as its telescopic mounting meant longer pipe sections could be drilled in, for a more efficient process. Both machines had the advantage of an electric drive, meaning they could be safely used inside buildings without any issues with exhaust gas. Stump-Franki Planung provided consultancy,

pile static measurements and planning and 3D collision testing for the project.

3D modelling prevents collisions

Retroactive foundation works on the new turbine deck required extreme precision in terms of both positional accuracy and the installation lengths of the piles. It was also important to avoid collisions with existing foundations and walls in the subsoil, or with power lines. To address these concerns, PORR’s in-house team conducted 3D modelling prior to beginning foundation works. The rewards of precision planning: no existing piles were impacted, and all boreholes were able to be drilled according to plan.

The Werne site contributes to the energy transformation

Werne is also an important site for RWE. By the end of this year, the power plant site will be home to one of the most innovative battery storage systems in Germany, which will ensure network stability in the event of reduced power feed-in from renewable energy sources. With this and other features, the site in Werne is making an important contribution to the success of the energy transformation.