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Braced Foundation

Presentation
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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

Geometry and components


Certification
Banzi, fist commercial project
Advantages and benefits
Gamesas offer
Exhibits

BRACED FOUNDATION
Gamesa Profile
Mission & Strategy

MISSION: EVERLASTING ENERGY EVERYWHERE

Leadership Operational efficiency


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Passion for the customer Focus on Investment

Value creation for special Flexibility to optimize future


interest groups/ opportunities for growth
stakeholders

ATTITUDES FOR SUCCESS PILLARS OF PERFORMANCE

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

Innovative foundation solution from ESTEYCO ENERGIA.


GAMESA has the exclusivity of this design

Significant improvement of the Cost of Energy, by:


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Optimizing the cost of the foundation (reduction of


CAPEX for a wind energy project)

Boosting turbine production thanks to an increase of


the hub height

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.

20-year experience in wind turbine


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foundation design and on-site technical
assistance
Track record: +5,000 WTG foundations
already built, including:
Slab foundations, also over soil improvement
treatments
Pile foundations
Anchored foundations

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

Confirmation of execution times


Execution costs as expected

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

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Income AEP increase


Hub height increase up to 4-5 m. Therefore, noticeable AEP increase, depending on the wind shear
Direct impact in CoE reduction (more significant than BOP cost reduction)

AEP increase +4m (G114 93m 2MW max power)


Wind Farm m/s K weibull Air dens Wind sehar AEP increase
WF 1 8,9 3,75 1,07 0,18 0,9%
WF 2 8,2 2,4 1,04 0,15 0,9%
WF 3 8,0 2,6 1,17 0,23 1,4%
WF 4 7,5 2,5 1,21 0,32 2,1%
WF 5 7,1 2,15 1,21 0,25 1,6%

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 (*)

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Bolt cage needed in the latter
phases of the construction, vs in the beginning
for standard foundation

Workgroups planning to be organized in


advance, as the foundation has different phases,
which need curing between them, but provides
additional flexibility to avoid workforce stops
(reassignment of resources, sequencing etc)
(*) Theoretical paces, for first units it is safer to think that execution time will be similar for both foundation solutions.

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

Reduction of execution risk as it enables the introduction of quality control


points in the different phases 12

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
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quality is provided thanks to the use of molds. The Lower
slab formwork ensures braces positioning.
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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.

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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

diam 16,5m diam 19,0m diam 16,5m diam 19,0m

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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:

Design of the foundation can be subcontracted to Gamesa or directly subcontracted to the


engineering company, in this case Esteyco, and

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
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Entrance to the WTG

BRACED FOUNDATION
EXHIBITS

1. Construction procces description

2. Execution planning

3. Engineering design
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1. Constructive details - molds

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

STEP 1.- STEP 2.- STEP 3.-


EXCAVATION AND BLINDING CONCRETE LOWER SLAB STEEL REINFORCEMENT LOWER SLAB FORMWORK AND CONCRETE
1. Excavation 1. Edge beam (P1,P2) 1. Steel reinforcement assembly
2. Formwork and electrowelded steel mesh 2. Lower slab (C1,Q1,Q2) 2. Formwork
3. Blinding concrete casting 3. Lower slab (C2,C3) 3. Concrete casting
4. Edge beam excavation 4. Lower slab to inner ring (A11,A12) 4. Formwork removal
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STEP 4.- STEP 5.- STEP 6.-


INNER RING COMPLETION FIRST STEP OF BACKFILLING UPPER SLAB SR AND INTERFACE ASSEMBLY
1. Steel reinforcement assembly 1. Backfilling both out and inside 1. Blinding concrete
2. Formwork the inner ring 2. Anchor cage assembly
3. Concrete casting 2. Compaction 3. Steel reinforcement
4. Formwork removal 3. Density tests

STEP 7.- STEP 8.-


UPPER SLAB FORMWORK AND CONCRETE FINAL STEPS: Backfilling, prestressing and grouting
1. Outer formwork
2. Inner formwork-Active anchorage 1. Final backfilling
3. MV pipes driving 2. Prestressing
4. Concrete casting 3. Seath grouting
5. Formwork removal 4. Second step of backfilling

BRACED FOUNDATION
BRACED FOUNDATION CONSTRUCTION PROCESS
STEP 0.- PRECAST BRACE CONSTRUCTION

Steel reinforcement and seath


Installation of the moulds Concrete casting
placement
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Cable driving and passive anchorage


Mould removal Storage
assembly
Production: One brace per mould and day

BRACED FOUNDATION
BRACED FOUNDATION CONSTRUCTION PROCESS
STEP 1.- EXCAVATION AND BLINDING CONCRETE

Excavation Formwork and steel mesh Blinding concrete casting 19

Edge beam excavation Edge beam 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)
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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
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Levelling of the braces and


Braces totally installed Lower slab completed
passive anchorage fitting

BRACED FOUNDATION
BRACED FOUNDATION CONSTRUCTION PROCESS
STEP 4.- INNER RING COMPLETION

A01-A10 Steel reinforcement assembly Formwork assembly Totally placed formwork 22

Concrete casting Formwork removal-Completed inner ring

BRACED FOUNDATION
BRACED FOUNDATION CONSTRUCTION PROCESS
STEP 5.- FIRST STEP OF BACKFILLING

First step of backfilling Outside Backfilling compactation Backfilling inside the inner ring
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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

Active anchorage assembly: Trumpet,


Blinding concrete Embedded flange placement
anchor body and additional
reinforcement 24

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

Concrete casting Formwork removal-Active anchorage Completed upper slab

BRACED FOUNDATION
BRACED FOUNDATION CONSTRUCTION PROCESS
STEP 8.- FINAL STEPS

Spacer, wedge plate and wedge Prestressing: Load appliance


Final Backfilling
placement 26

Seath injection with grout


Prestressing control: Elongation Anchor head sealing: Cut of protuding cables,
measurement and filling the head hollow with concrete

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

1 EXCAVATION 8-EqExc 8-EqExc


1BISBLINDING CONCRETE 4-Eq01
2 LOWER SLAB REINFORCEMENT 8-Eq02 8-Eq02
WTG001 3 LOWER SLAB FORMWORK AND CONCRETE 8-Eq01 4-Eq01 2-Eq06
5 INNER RING COMPLETION 8-Eq03 8-Eq03 4-Eq06
6 FIRST STEP OF BACKFILLING 8-Eq04 8-Eq04
7 UPPER SLAB REINFORCEMENT AND INTERFACE 1-Eq06 8-Eq06 8-Eq05
8 UPER SLAB FORMWORK AND CONCRETE 8-Eq05 2-Eq06

1 EXCAVATION 8-EqExc 8-EqExc


1BISBLINDING CONCRETE 4-Eq01
2 LOWER SLAB REINFORCEMENT 8-Eq02 8-Eq02
WTG002 3 LOWER SLAB FORMWORK AND CONCRETE 8-Eq01 4-Eq01 2-Eq06
5 INNER RING COMPLETION 8-Eq03 8-Eq03 4-Eq06
6 FIRST STEP OF BACKFILLING 8-Eq04 8-Eq04
7 UPPER SLAB REINFORCEMENT AND INTERFACE 1-Eq06 8-Eq06 8-Eq05
8 UPER SLAB FORMWORK AND CONCRETE 8-Eq05 2-Eq06

1 EXCAVATION 8-EqExc 8-EqExc


1BISBLINDING CONCRETE 4-Eq01
2 LOWER SLAB REINFORCEMENT 8-Eq02 8-Eq02
WTG003 3 LOWER SLAB FORMWORK AND CONCRETE 8-Eq01 4-Eq01 2-Eq06 28
5 INNER RING COMPLETION 8-Eq03 8-Eq03 4-Eq06
6 FIRST STEP OF BACKFILLING 8-Eq04 8-Eq04
7 UPPER SLAB REINFORCEMENT AND INTERFACE 1-Eq06 8-Eq06 8-Eq05
8 UPER SLAB FORMWORK AND CONCRETE 8-Eq05 2-Eq06

1 EXCAVATION 8-EqExc 8-EqExc


1BISBLINDING CONCRETE 4-Eq01
2 LOWER SLAB REINFORCEMENT 8-Eq02 8-Eq02
WTG004 3 LOWER SLAB FORMWORK AND CONCRETE 8-Eq01 4-Eq01 2-Eq06
5 INNER RING COMPLETION 8-Eq03 8-Eq03 4-Eq06
6 FIRST STEP OF BACKFILLING 8-Eq04 8-Eq04
7 UPPER SLAB REINFORCEMENT AND INTERFACE 1-Eq06 8-Eq06 8-Eq05
8 UPER SLAB FORMWORK AND CONCRETE 8-Eq05 2-Eq06

1 EXCAVATION 8-EqExc 8-EqExc


1BISBLINDING CONCRETE 4-Eq01
2 LOWER SLAB REINFORCEMENT 8-Eq02 8-Eq02
WTG005 3 LOWER SLAB FORMWORK AND CONCRETE 8-Eq01 4-Eq01 2-Eq06
5 INNER RING COMPLETION 8-Eq03 8-Eq03 4-Eq06
6 FIRST STEP OF BACKFILLING 8-Eq04 8-Eq04
7 UPPER SLAB REINFORCEMENT AND INTERFACE 1-Eq06 8-Eq06 8-Eq05
8 UPER SLAB FORMWORK AND CONCRETE 8-Eq05 2-Eq06

EqExc-Excavation teamExcavation team


Eq-01: Team 01 Comprised of four workers, responsible for blinding concrete and lower slab formwork and concrete casting
Eq02: Team 02 Comprised of six workers, responsible for placing lower slab reinforcement
Eq03: Team 03 Comprised of four workers, responsible for inner ring whole completion (reinforcement, formwork and concrete)
Eq04: Team 04 Comprised of one worker, supporting machinery on manual compaction processses
Eq05: Team 5 Comprised of 4 to 6 workers, responsible for upper slab reinforcement, anchor cage placement, formwork and concrete
Eq06: Team 6 Comprised of two workers, for auxiliary purposes, such as upper slab blinding concrete, and formwork removal

BRACED FOUNDATION
DESIGN ENGINEERING
CONSTRUCTIVE DETAILS +0m, +4m, piles

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+ 0 m with refilling
+ 4 m with out refilling

+ 4 m with micropiles + 4 m with refilling


BRACED FOUNDATION
CONSTRUCTIVE DETAILS
Molds andMOLD
BRACED formworks

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BRACED FOUNDATION
CONSTRUCTIVE DETAILS
Molds and formworks
FORMWORK DESIGN

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BRACED FOUNDATION
Thank you

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GAMESA 2.0-2.5 MW PLATFORM PRESENTATION