PROJECT CONDITIONS 1.5–2.5 m waves | Strong currents | 2–10 m depth | 18.5 m water-level variation.
SOLUTION AIPL engineered a Modular Pump Pontoon using SIFJ (Steel-Integrated Floating Jetty) for reservoir pumping.
RESULT Installed in <2 months | Operational since 2019 | 400 m³/hr pumping capacity | 7+ years failure-free operation.
Pump Configuration
2 Submersible Pumps
20 kW each
Capacity: 200 m³/hr each
Total Water Supply Capacity:400 m³/hr
“After the first vendor failed, we needed a pump pontoon that could perform reliably in real reservoir conditions. AIPL delivered a floating pump house solution that has been operating continuously for more than seven years without any issues.” — Tejas Constructions & Infrastructure Pvt. Ltd.
1. When the First Pontoon Failed
In 2018, the Beohari Water Supply Scheme faced a serious crisis.
A pump pontoon supplied by a generic vendor failed within just one year of commissioning. The structure could not survive the harsh reservoir conditions at Bansagar Dam — high wind-generated waves, strong currents, and extreme seasonal water-level variations.
The Impact
Structural damage and loss of major pontoon components
Disruption to critical water supply operations
Financial losses and project delays for the EPC contractor
Loss of confidence from the government authority
With water supply at risk and timelines under pressure, the EPC contractor needed more than a replacement.
They needed a reliable engineering partner who could design a solution for real reservoir conditions, not theoretical assumptions.
That’s when Acquafront Infrastructure Private Limited (AIPL) stepped in.
2. The Challenge: Engineering for Extreme Reservoir Conditions
Bansagar Dam behaves less like a calm lake and more like an inland sea.
Hydrological and Site Conditions
Waterbody Type: Large inland reservoir Water Depth Range: 2–10 meters
Wave & Wind Conditions
Wind-generated waves reaching 1.5–2.5 meters
Strong currents
Continuous dynamic wave loading on floating structures
Seasonal Water Level Fluctuation
FRL: 341.65 m
MDDL: 323.10 m
Vertical variation: ~18.5 meters
These extreme variations meant the floating pump house had to:
Maintain pump submergence at all water levels
Absorb wave energy without fatigue or instability
Operate continuously 24×7 under dynamic reservoir conditions
The earlier pontoon failed precisely because it was not engineered for these realities
3. The AIPL Solution: SIFJ Modular Pump Pontoon
AIPL engineered a custom modular pump pontoon based on its SIFJ (Steel-Integrated Floating Jetty) technology, specifically designed for heavy-duty reservoir pumping.
Why SIFJ Was Selected
Previous generic pontoon failed under harsh reservoir conditions
Required high wave resilience
Needed long-term corrosion resistance
Required modular adaptability for 18.5 m water-level variation
Lower lifecycle maintenance compared to steel or plastic drum pontoons
Engineering Philosophy
The system was designed using a hybrid structural approach:
Steel-integrated structural framework for rigidity
Composite flotation system for wave absorption
Structural design optimized for continuous heavy pump operation
Design Standards Followed
The pontoon system was engineered in accordance with:
IS 800
IS 875
BS 6349 Part 6
IRC 6
Load Cases Considered
Continuous dynamic wave loading
Wind-generated waves 1.5–2.5 m
Operational loads from pump equipment
Seasonal water-level variation (~18.5 m)
Stability & Buoyancy Strategy
Composite floats integrated with a steel framework
Engineered to maintain pump submergence across all reservoir levels
Structural system designed to absorb wave energy and prevent fatigue
Corrosion Protection Philosophy
Use of corrosion-resistant materials
Hybrid steel-composite structure
Significantly reduced maintenance compared to conventional steel pontoons
4. Technical Configuration of the Floating Pump Pontoon
The final executed configuration included:
Main Pontoon Platform
Size: 3.5 m × 6 m
Additional Modules
1 Module: 3.5 m × 6 m
2 Modules: 6 m × 2 m
Total Floating Area:45 m²
Structural Design Parameters
Design Live Load: 2 tonnes
Minimum Draft: 1 m
Design Life: 10 years (Operational for 7+ years and continuing)
Mooring System
2-point deck-to-shore mooring system
Access System
Floating gangway: 12 m
This configuration ensured structural stability, safe access, and operational reliability even under dynamic reservoir conditions.
5. Execution Under Complex Site Constraints
Fabrication & Logistics
Fabrication Location: Factory
Materials Used: MS and HDPE composite system
Transportation: Truck / Trailer
However, site logistics created an additional challenge.
Due to difficult terrain, heavy equipment like a Hydra crane could not directly access the installation location.
Innovative Deployment Strategy
The pontoon was:
Deployed 4–5 km away from the final site
Assembled modularly
Towed by boat across the reservoir to the final location
Installation Highlights
Modular assembly allowed rapid deployment
On-site installation completed in just 1 day
Total project completion: Under 2 months
6. The Result: 7+ Years of Proven Reservoir Performance
Since commissioning in 2019, the AIPL pump pontoon has been operating reliably under the same extreme conditions that destroyed the previous structure.
Operational Capacity
400 m³/hr water supply capacity
Continuous 24×7 operation
Performance Outcomes
Zero structural failure in 7+ years
Stable under 1.5–2.5 m waves
Adaptation to 18.5 m seasonal water level variation
AIPL specializes in modular maritime and floating-infrastructure platforms for energy, water, marine, transport, construction, pumping and tourism sectors, supported by a decade of proven engineering.
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