Beruflich Dokumente
Kultur Dokumente
Presentation
1
December 15
GAMESA 2.0-2.5 MW PLATFORM PRESENTATION
Contents
Gamesa Profile: extensive experience throughout the value chain
Braced foundation
Improving the Cost of Energy
Esteyco Energia 2
BRACED FOUNDATION
Gamesa Profile
Mission & Strategy
BRACED FOUNDATION
Gamesa Profile
Wide experience throughout the value chain
WIND FARM WIND TURBINE WIND TURBINE
DEVELOPMENT MANUFACTURING SERVICES
7.1 GW 32.7 GW 20.6 GW
Data as of 2Q2015
BRACED FOUNDATION
Braced Foundation
Improving the Cost of Energy
BRACED FOUNDATION
Braced Foundation
Esteyco Energia
Esteyco Company with a long-lasting and unique international experience in civil engineering
and wind energy
Specialist in geotechnical and structural engineering for wind sector.
BRACED FOUNDATION
Braced Foundation
Geometry and components 5 elements
UPPER SLAB
CENTRAL RING
BRACES x6
REFILL
EDGE BEAM
LOWER SLAB
BRACED FOUNDATION
Braced Foundation
Conformity Statement available from GL
BRACED FOUNDATION
Braced Foundation
Banzi-First commercial project
Civil work concluded jun-15. Basilicata, Southern Italy
15x G97-2.0 MW IIA T90 Turn-key project. Final client not Gamesa
BRACED FOUNDATION
Advantages and benefits
Reduction of CoE
Cost CAPEX reduction
About 30-40% reduction in materials-Concrete and reinforced steel, but
higher cost for crane, man hours and tooling than standard foundation, in total
Braced foundation +4m around 3-10% cheaper than equivalent +0m standard foundation
Bigger impact in sites where soil substitution is needed
10
BRACED FOUNDATION
Advantages and benefits
Execution timming
Execution of the first foundation is longer than standard one, due to different
phases of curing --- 15 days from start of construction vs 10 days for standard foundation, but
Total execution time is shorter as execution rates are improved ---One each 2 days
vs one each 2,5/3 days for the standard foundation (*)
11
Bolt cage needed in the latter
phases of the construction, vs in the beginning
for standard foundation
BRACED FOUNDATION
Advantages and benefits
Amount and delivery of concrete & execution risk
Less concrete needs per foundation --- around 220 m3 vs 330 m3 for standard foundation, and
Smaller concrete plant needed --- brace foundation concrete delivery can be divided into a two
day cycle of 130m3 the first day and 90m3 the next day vs the 330m3 delivered in a single day, every three days for
the standard foundation
350
300
The concept seems more complex, but its construction is
splitted in smaller and simpler phases.
250
200 The most critical part (the braces) are precast, but industrial
150
quality is provided thanks to the use of molds. The Lower
slab formwork ensures braces positioning.
100
50
standard foundation
0 braced foundation
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
BRACED FOUNDATION
Advantages and benefits
Design flexibility to adapt to soil characteristics
Braced foundation grows bigger with less cost increase than standard one
- E.g. for an increase of 3,5 m of diameter, additional 41m3 of concrete and 3,8Tn of steel are needed, vs 181m3
and 13,2Tn for the standard foundation
- Thus, modifying design to comply with a number of different soils can be done at lower costs.
- This is an advantage when geotechnical info is scarce, but investment decisions are to be made.
13
500 488 50
43,94
450 45
400 40
350 307 35 30,7 30,3
300 273 30 26,5
250 232 25
200 20
150 15
100 10
50 5
0 0
std concrete braced concrete std steel braced steel
13
BRACED FOUNDATION
Gamesas offer
Braced foundation solution. A complete package
The execution of this foundation does not change anything related with the scope, it
just optimizes the projects profitability. The scope remains as per current situation:
Gamesa could execute the BOP and/or, in case the BOP is under the customers scope, assign 14
the technology license to the customer and provide support in
Cost analysis and assessment of possible hub height increase to target an overall improvement
of the project Cost of Energy (on a case-by-case basis).
Technical support from Gamesas BoP Department to clients BoP engineering companies.
Support in the definition of the most efficient construction plan and resources (molds,
formworks, RFQ definition)
Engineering support and on-site technical assistance provided by Esteyco
BRACED FOUNDATION
Design optimization
Entrance through the foundations ring
Main advantages
Allows extra hub height: +5m/+6m
Ground and other elements will be accessible from the found level optimizing maintenance tasks
External ladder and tower door removal, potential for additional savings
Structural design validated, final layout and other details on going. Elevator will not reach
foundation ring, access to upper slab and elevator through internal ladder
15
BRACED FOUNDATION
EXHIBITS
2. Execution planning
3. Engineering design
16
BRACED FOUNDATION
BRACED FOUNDATION CONSTRUCTION SEQUENCE
STEP 0.- (SIMULTANEOUS)
PRECAST BRACE CONSTRUCTION
1. Installation of the moulds
2. Installation of steel and prestressing cable seath
3. Concrete casting
4. Mould removal and storage
5. Cable driving and passive anchorage assembly
BRACED FOUNDATION
BRACED FOUNDATION CONSTRUCTION PROCESS
STEP 0.- PRECAST BRACE CONSTRUCTION
BRACED FOUNDATION
BRACED FOUNDATION CONSTRUCTION PROCESS
STEP 1.- EXCAVATION AND BLINDING CONCRETE
BRACED FOUNDATION
BRACED FOUNDATION CONSTRUCTION PROCESS
STEP 2.- LOWER SLAB STEEL REINFORCEMENT
Marking out of the elements Edge beam steel reinforcement (P1,P2) Lower slab SR (C1,Q1)
20
Lower slab SR (Q1,Q2) Lower slab SR (C1,C3) Lower slab to inner ring SR (A11,A12)
BRACED FOUNDATION
BRACED FOUNDATION CONSTRUCTION PROCESS
STEP 3.- LOWER SLAB FORMWORK AND CONCRETE CASTING
Preassembled formwork placement Manoeuvre of the braces ready to start Installation of the braces
21
BRACED FOUNDATION
BRACED FOUNDATION CONSTRUCTION PROCESS
STEP 4.- INNER RING COMPLETION
BRACED FOUNDATION
BRACED FOUNDATION CONSTRUCTION PROCESS
STEP 5.- FIRST STEP OF BACKFILLING
First step of backfilling Outside Backfilling compactation Backfilling inside the inner ring
23
Inner backfilling compactation Structure boundaries compaction Sand cone test (site) and moisture test
(laboratory)
BRACED FOUNDATION
BRACED FOUNDATION CONSTRUCTION PROCESS
STEP 6.- UPPER SLAB STEEL REINFORCEMENT AND INTERFACE ASSEMBLY
Whole assembly of the anchor cage Laying of steel reinforcement Completed steel reinforcement
BRACED FOUNDATION
BRACED FOUNDATION CONSTRUCTION PROCESS
STEP 7.- UPPER SLAB STEEL FORMWORK AND CONCRETE CASTING
Formwork of the head of the cables Outer formwork MV Cable pipes driving and further
auxiliary works 25
BRACED FOUNDATION
BRACED FOUNDATION CONSTRUCTION PROCESS
STEP 8.- FINAL STEPS
BRACED FOUNDATION
PROCESS ENGINEERING
SINGLE FOUNDATION EXECUTION PLANNING
SINGLE FOUNDATION PLANNING
W1 W2 W3 W4 WORKERS PER TEAM
ID CONSTRUCTION STEPS (NO MACHINERY)
M T W TH F M T W TH F M T W TH F M T
1 EXCAVATION AND BLINDING CONCRETE
1.1 EXCAVACIN GENERALN/A N/A
1.2 EDGE BEAM EXCAVATION N/A
1.3 OVERALL BLINDING CONCRETE 3 4
1.4 EDGE BEAM BLINDING CONCRETE 1 4
2 LOWER SLAB STEEL REINFORCEMENT
2.1 MARKING OUT 1 6
2.2 EDGE BEAM STEEL REINFORCEMENT (P1,P2) 3 6
2.3 LOWER SLAB C1,Q1,Q2 4 4 6
2.4 LOWER SLAB C1,C3 2 6
2.5 LOWER SLAB A11,A12 2 6
3 LOWER SLAB FORMWORK AND CONCRETE CASTING
3.1 FORMWORK PREASSEMBLY 2 2
3.2 INNER FORMWORK PLACEMENT 1 2
3.3 BRACES INSTALLATION AND LEVELLING 3 4 27
3.4 OUTER FORMWORK 2 4
3.5 CONCRETE CASTING 4 4
3.6 2 4
4 INNER RING COMPLETION
4.1 STEEL REINFORCEMENT 6 6
4.2 FORMWORK 2 5 4
4.3 CONCRETE CASTING 3 4
4.4 FORMWORK REMOVAL 4 4
5 FIRST STEP OF BACKFILLING
5.1 FIRST STEP OF BACKFILLING 8 8 1
6 UPPER SLAB STEEL REINFORCEMENT AND INTERFACE
6.1 BLINDING CONCRETE 1 2
6.2 ACTIVE ANCHORAGE ASSEMBLY 2 2
6.3 INTERFACE ASSEMBLY 6 2 2
6.4 STEEL REINFORCEMENT 6 6
7 UPPER SLAB FORMWORK AND CONCRETE CASTING
7.1 MV PIPES 2 2
7.2 ACTIVE ANCHORAGE FORMWORK 2 2
7.3 OUTER FORMWORK 4 4
7.4 CONCRETE CASTING 2 4
7.5 FORMWROK REMOVAL 2 2
8 FINAL STEPS
8.1 FINAL BACKFILLING
8.2 PRESTRESSING 3
8.3 SEATH GROUTING ONCE REACHED THE SPECIFIED CONCRETE COMPRESSIVE STRENGTH (32 Mpa) AND ALWAYS WITHIN FOUNDATION CURING PERIOD BEFORE TOWER ASSEMBLY 3
BRACED FOUNDATION
PROCESS ENGINEERING
GENERAL SEQUENCE, EXAMPLE 5 FOUNDATIONS W1 W2 W3 W4 W5
FOUNDATION ID CONSTRUCTION STEPS
M T W TH F M T W TH F M T W TH F M T W TH F M T W TH F
BRACED FOUNDATION
DESIGN ENGINEERING
CONSTRUCTIVE DETAILS +0m, +4m, piles
29
+ 0 m with refilling
+ 4 m with out refilling
30
BRACED FOUNDATION
CONSTRUCTIVE DETAILS
Molds and formworks
FORMWORK DESIGN
31
BRACED FOUNDATION
Thank you
32