Crossing the Uncrossable: Rebuilding a 400 kV Line Across the Ganges

Rebuilding a 400 kV line across the Ganges River demanded breakthrough conductor design, marine-grade execution, and precision engineering—setting new benchmarks for long-span transmission under extreme conditions.

Challenge

Rebuilding a 400 kV transmission line across the mighty Ganges presented a unique set of engineering and environmental challenges. Monsoon flooding had washed away a tower positioned in the middle of the riverbed, and the constant shifting of the river course made restoration extremely difficult.

Conventional stringing methods were unviable across such an expanse — the required span of 1,102 metres was nearly three times the normal 300–400 m range. Severe right-of-way constraints and lack of site access further added to the complexity.

Solution

Sterlite Electric’s MSI team developed a new conductor design with a carbon-composite core (ACCC ULS – ultra-low-sag) to meet the project’s mechanical and thermal demands.

Specialised stringing equipment and manpower were mobilised using barges to operate safely in deep-water conditions. Custom tools and tackles were engineered to match the conductor’s unique specifications, while strict marine-grade HSE protocols were implemented to safeguard operations.

An electronic dynamometer with remote sensors continuously monitored pulling tension, ensuring absolute control and safety throughout the conductor installation.

Impact

The project successfully delivered a 1,102 m span stringed with the new conductor design, marking a breakthrough in long-span river-crossing execution. It set new industry benchmarks for safety, precision, and project delivery under extreme conditions, while restoring a critical transmission corridor that supplies power across eastern India.

Recognition

This project earned the IPMA Gold Award for Global Project Excellence — a first-of-its-kind achievement for India’s transmission sector. The award recognised Sterlite Electric’s innovative use of HTLS ULS conductors in a quad configuration at 400 kV and its exceptional execution standards under highly adverse conditions.

The 400 kV Ganges River Crossing showcases how engineering ingenuity, customised design, and world-class safety practices can overcome nature’s toughest challenges. Sterlite’s MSI business continues to pioneer solutions that expand the boundaries of transmission construction, connecting critical infrastructure where it’s needed most.