East Alton, Ill., November 17, 2011 — Helmkamp Construction Co. is nearing completion on its portion of a dry flue gas desulfurization project to improve the quality of emissions at Dynegy's 1,800 MW coal-fired Baldwin Energy Complex in Baldwin, Illinois. Once the new systems come online, Dynegy Baldwin's sulfur dioxide emissions are expected to be the lowest of any coal-fired units in the state.
Helmkamp is completing $45 million in civil work including site preparation and installation of foundations for baghouses and dry scrubber equipment, the specialized equipment that removes sulfur dioxide from the coal plant's exhaust flue gases.
In addition, Helmkamp installed foundations for duct supports, support buildings, utility racks and silo foundations. Helmkamp also is performing all excavations for the required mechanical and electrical underground installations.
The 36-month project was complex and challenging, demanding precise coordination and communications to work within the fully operational power plant on a tight site between the Dynegy Baldwin plant and Baldwin Lake.
Helmkamp placed more than 4,000 anchor bolts and 2,500 auger cast piles at 60-foot depths with no reworks. They achieved that accuracy using a Robotic Total Station and desktop software to perform layout tasks, which allowed the team to easily re-establish pile locations as needed later in the project.
The project required about 30,000 cubic yards of concrete, much of it poured during two cold, snowy and icy winters. The largest single concrete pour was for the lime storage and waste ash silo foundation, in which three concrete pump trucks simultaneously poured a total 2,200 cubic yards of concrete in a limited access area. The second largest pour was about 1,300 cubic yards.
Numerous underground obstructions not shown on the drawings were located and identified during many of the projects excavations. These and other related issues were quickly resolved to keep the project on schedule and within budget.
Helmkamp performed 280,000 work-hours on the project with only one recordable incident. In 2008, Helmkamp received a zero injuries award from the National Maintenance Agreements Policy Committee for 57,321 injury-free self performed man-hours on the Dynegy Baldwin job. Helmkamp received this same award from the National Maintenance Agreements Policy Committee for 102,800 injury free work hours for the 2009 calendar year.