Large-scale construction site in Greece. Height-access specialist GEDA deploys customised solutions to support the construction of a new lignite block

A new block is being built at the Ptolemaida lignite power station located about 600 km north-west of Athens in Greece. In addition to an increase in output, the Block V expansion is incorporating complex modernisation measures. The height access technology on the construction site is being supplied by six hoist solutions from GEDA-Dechentreiter GmbH & Co. KG.

The 660 megawatt power station is a turnkey construction project by Hitachi Power Europe based in Duisburg together with Terna, a Greek power plant engineering firm and highly-regarded construction group. The contract for the multi-billion Euro project was concluded in March 2013 with Greece’s state and largest energy supplier energy supplier, Public Power Corporation (PPC).
The new lignite block Number V will partially replace other power station blocks in Ptolemaida some of which are up to 50 years old. The large-scale project is mainly being financed by funds from international consortia. These include the Federal Republic of Germany which is providing export assistance and has assumed the credit guarantees through Hermes guarantees. This has enabled the Government to ensure the export of German products in order to secure jobs in Germany and safeguard suppliers from the risk of a payment default.

Huge flexibility and customised solutions are required

On the construction site of the new block the huge project requires height access technology specialists also able to offer flexible and customisable solutions. In order to ensure the smooth transportation of employees and building materials, Stagakis Ltd., the Athens-based construction company responsible, decided to install six hoist solutions from the manufacturer GEDA-Dechentreiter GmbH & Co. KG.
Extreme flexibility is required because the hoists have to be installed on a wide range of different structures on the construction site. Pantelis Stagakis, the managing director of Stagakis, is impressed with the technology on offer from GEDA. “On the construction site we were faced with several complex tasks, in particular the height of the individual structures rising daily, presented us with immense challenges, as the installation height of the cranes and the industrial hoist solutions also had to increase every day in line with the height of the building construction. It must also always be possible to disassemble and reassemble the hoists at another location so as not to impede construction progress.” However, thanks to the unique know-how of the GEDA experts and the experience of Stagakis Ltd. these challenges were overcome together, continues the Stagakis managing director.

Versatile in both interior and exterior use

Here three GEDA Multlift P12 “Comfort” devices for the efficient transportation of people and materials have proven their worth as highly versatile pieces of equipment which meet all the requirements on the mega-construction site. The name says it all: Whether on the external side of the pylons, inside the shafts or flexibly adjustable through the special anchorings on different steel constructions, the modular design of the entire GEDA Multilift range can provide the appropriate hoist solution for virtually every construction site requirement. The compact, pre-installed base unit, which is composed of a car, enclosure, flat cable bin and drive is delivered as one unit.
The three GEDA Multilift P12 devices in use in Ptolemaida transport 1200 kg and/or 12 people quickly and safely up and down. The spacious “B-design” platform with its dimensions of 1.4 x 2.6 x 2.1 metres ensures safe transportation along all building structures. Despite the high load capacity, the personnel and materials hoist impress with their low anchoring forces – and each with only one mast.

GEDA customised solution for cooling tower construction

The cooling tower of the new Block V is a very important aspect of the expansion Ptolemaida power station. To assemble the external sheathing and to enable workers and building materials to access the formworks, a GEDA PH 2032 650 Single personnel and material hoist has been installed.
The particular geometry of the cooling tower placed huge challenges for the lift assembly as due to the incline of the exterior wall, both the mast and the hoist itself had to be adapted to the changing geometry of the tower. Therefore, the exit to the formworks from the GEDA PH via an additional “D”-Door was also a customised solution developed by GEDA.
The free-standing mast projection of 9 metres enables further complete landing levels to be accessed.
Thanks to the power pack with a load capacity of 2,000 kg or 25 people, a lifting height of 400 metres and a hoisting speed of up to 90 m/min, rapid construction progress on the cooling tower is ensured.

Two GEDA 2 PK crane operator hoists – safety and efficiency

Two crane operator hoists are also providing valuable transportation services on a free-standing crane on the Ptolemaida building site. And this is another reason why Stagakis Ltd. chose GEDA, as thanks to the GEDA 2 PK rack and pinion hoists those reckless and arduous climbs have been consigned to the past and the crane operator can now reach his workplace quickly and above all safely.
The GEDA 2 PK is designed to transport two persons with a load capacity of 200 kg. Therefore, any materials required for maintenance tasks can also be transported upwards. The hoisting speed is 25 m/min with a maximum lifting height of 150 metres. On the power station construction site in Ptolemaida, GEDA installed two customised solutions with a lifting height of 186 m.
Once the base unit is assembled and anchored, the aluminium ladder sections, weighing 22 kg, are installed through the open cabin roof and, using the patented quick-release connections, easily assembled without any screws. The hoist is operated from the control panel in the car and from the stop position. The flexible system of the GEDA 2 PK is suitable for all types of cranes from all manufacturers.
The car of the GEDA 2 PK has an entry ramp, so that access to the crane is completely safe. Two GEDA landing level safety gates guarantee the safe transition from the cabin to the crane. The crane operator hoist can act as a life saver in an emergency since the emergency rescue of unconscious or ill crane operators can be carried out very quickly by the GEDA 2 PK.

Planned start 2020

Not without reason did Stagakis Ltd. decide to install height access solutions from GEDA. “GEDA has made it possible to equip this complex construction site and its many special requirements with the appropriate hoist solution for each purpose. Whether a person and material hoist or crane operator hoist – GEDA was able to supply us with the right hoisting technology” says managing director, Pantelis Stagakis.
With the expansion of the Ptolemais V lignite power station, GEDA has concluded another successful project in collaboration with prestigious partners. Bavarian height access technology is also being deployed currently in the expansion works of the power station in Opole.

The new Ptolomaida V block is scheduled to be connected to the grid in 2020. Whereas environmentalists view the issue of lignite-generated electricity extremely critically, the construction of the new power station will deliver many commercial benefits. For example, during peak periods up to 2,000 people will be employed on the mega-construction site, and more than 100 companies are providing a range of construction and assembly services and supply agreements have been concluded with many other companies for raw materials and other materials.