KPTCL 400 KV Transmission Tower Foundation
Karnataka's first 400 KV transmission tower foundation pour — 780 m³ placed in a single continuous pour with zero cold joints.
Project details
| Client | KPTCL (Karnataka Power Transmission Corporation Limited) |
|---|---|
| Location | Karnataka |
| Grade(s) supplied | M40 (low-heat, GGBS-blended) |
| Total quantity | 780 m³ |
| Duration | Single continuous pour |
Technical challenge
A 400 KV tower foundation cannot tolerate a cold joint anywhere in the raft — any discontinuity becomes a long-term durability and load-transfer risk on a structure carrying live transmission at extreme wind loading. The pour had to run uninterrupted at high volume, in a location with limited site access, while keeping the peak core temperature and the core-to-surface differential inside mass-concrete limits.
Our solution
We designed a low-heat M40 mix with a high GGBS replacement to flatten the heat-of-hydration curve, and held retardation and slump retention long enough for the last truck in the sequence to arrive workable. Plants were sequenced with a fixed truck headway so the placing face never starved, standby mixers and a backup pump were staged on site, and embedded thermocouples tracked core and surface temperature through the pour and the curing window. The full 780 m³ went in as one monolithic placement.
Client appreciation
"Alpha Concrete delivered Karnataka's first 400 KV tower foundation pour — 780 cum in a single continuous pour, without a single interruption. The mix, the temperature control and the truck sequencing were all exactly as planned."
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