Leipheim

New gas power plant

Frankip piles for deep foundations at a gas turbine power station in Bavaria

Deep foundations for heavy loads in power plant construction

When constructing power plants, heavy loads must be safely transferred to the subsoil. The power plant’s gas turbine alone weighs around 300 tonnes. The foundations therefore had to be tailored to the structural requirements of the technical installations and the geological conditions of the site. The subsoil in Leipheim consists of sandy-clay loess loam as well as load-bearing Quaternary gravel at depths of around ten metres. Below this lie Tertiary silts and clays of the Upper Freshwater Molasse. These subsoil conditions formed the basis for the choice of foundation concept.

286 Frankipiles NG® for the pile foundation

A total of 286 Frankipiles NG® with diameters of 51, 56 and 61 cm were manufactured for the power plant’s deep foundation. The piles reached lengths of around twelve metres and transfer the loads from the plant equipment into load-bearing soil layers. Frankipiles NG® are a type of displacement pile system and are used in special civil engineering for the deep foundation of industrial, energy and infrastructure structures. The selected pile system was tailored to the project-specific load requirements and ground conditions. Prior to construction, various foundation options were investigated. For the variant ultimately implemented using Frankipiles NG®, a project-specific comparative calculation showed a reduction of around 50 per cent in CO₂ emissions generated during production compared with the originally planned pile system.

Pile load tests in preparation for construction

Before foundation work began, static and dynamic pile load tests were carried out. The tests served to verify the load-bearing behaviour and the design of the pile foundation. The results formed the basis for the planning and execution of the deep foundation works on the power station site.

Foundation works within a tight timeframe

The power station project was characterised by a short construction period. The foundation works had to be integrated into the overall construction schedule and co-ordinated with the other trades. Thanks to continuous co-ordination between the client and those involved in the project, the pile foundation works were carried out in accordance with the project requirements.

Foundation for the new power station in Leipheim

The installation of 286 Frankipiles NG® laid the foundation for the construction of the gas turbine power station in Leipheim. The pile foundation transfers the load from the technical installations into the load-bearing subsoil, thereby forming an essential prerequisite for the subsequent use of the power station site.