Zhangjiagang Shazhou Power Plant Phase I Coal Yard Space Frame Project
Published On: October 21, 2026
Project Overview
Bafang Steel Structure delivered a complete design-and-build space frame enclosure for the Phase I coal yard of the Shazhou Power Plant in Zhangjiagang, Jiangsu Province. The project converts an open coal stockyard into a fully enclosed storage facility, covering approximately 45,600 m² with a clear span of 120 m and no internal columns. Engineering, fabrication and erection were completed within an eight-month programme, from detailing through final acceptance.
Project Background
Coal-fired power stations along the Yangtze River operate under strict requirements for fugitive dust control. The owner needed a permanent enclosure that would allow continuous coal handling by stacker-reclaimer, resist typhoon-season wind loads, and pass environmental acceptance without interrupting power generation.
- Location: Zhangjiagang, Jiangsu Province, China
- Facility: Phase I coal storage yard, coal-fired power plant
- Storage capacity: approximately 150,000 t of coal retained under cover
- Operating constraint: stacker-reclaimer rail system kept in service throughout construction
Structural Solution
A bolt-ball space frame with square pyramid units was specified for its favourable stiffness-to-weight ratio over a 120 m clear span. Spherical nodes with high-strength bolts allow factory-controlled tolerances and fast site assembly, while the double-layer configuration distributes wind and snow loads evenly onto the perimeter columns.
| Item | Specification |
|---|---|
| Enclosed area | 45,600 m² (120 m span × 380 m length) |
| Clear span | 120 m single span, no internal columns |
| Structural type | Bolt-ball space frame, square pyramid units |
| Node system | High-strength bolted spherical nodes |
| Roof cladding | 0.6 mm colour-coated steel sheet with insulation |
| Skylight ratio | Approx. 8% of roof area, polycarbonate panels |
| Steel consumption | Approx. 36 kg/m², total approx. 1,640 t |
| Eave / ridge height | 12 m / 46 m |
| Wind load | 0.45 kN/m², 50-year return period |
| Seismic design | Intensity 7, 0.10 g |
| Snow load | 0.40 kN/m² |
| Design service life | 50 years |
Scope of Supply
- Structural design, space frame detailing and BIM coordination
- Factory fabrication of nodes, members, bolts and purlins
- Shot blasting and anti-corrosion coating system
- Marked, export-packed and delivered components to site
- Erection of space frame, purlins and roof cladding
- As-built drawings, mill certificates and inspection records
Construction Challenges and Solutions
Erection over a live stockyard. A staged high-altitude assembly sequence with temporary support towers allowed the space frame to be erected in balanced segments, keeping coal handling continuous beneath the working face.
Typhoon-season wind exposure. Erection windows were planned against site wind monitoring, with temporary cable bracing and partial cladding applied to stabilise open areas after each shift.
Dust control during construction. The existing sprinkler system remained operational, and sealed working platforms limited dust migration beyond the yard boundary.
Corrosive service environment. Coal dust combined with river humidity required a coating system specified for C3-C4 exposure, with galvanized purlins and sealed node caps to protect bolted connections.
Project Results
- Enclosure completed in eight months, with erection sequencing coordinated to power plant operations
- Fugitive dust generation reduced by more than 90% compared with the previous open stockyard
- Zero lost-time incidents and zero interruption to power generation during construction
- Passed environmental acceptance at first inspection
- Coal handling equipment fully operational inside the enclosed yard
Client Feedback
"The space frame was erected over our operating stockyard without interrupting coal supply. Coordination between fabrication, delivery and site lifting was well managed, and the enclosure now meets our environmental commitments."
— Project Manager, Phase I Coal Yard Enclosure, Shazhou Power Plant
Why Bafang Steel Structure
Founded in 1999, Bafang Steel Structure is a professional steel structure group providing design, detailing, fabrication and installation support. With an annual production capacity of approximately 200,000 t of steel components, the company has delivered large-span space frames, trusses and steel buildings for power plants, transportation hubs, industrial facilities and public projects. For coal yard enclosures, our engineering team coordinates structural design, dust control requirements, erection sequencing and export logistics around continuous plant operation.
