Wind Tower Foundations 2 Concrete Solutions for Wind Tower Foundations Contents Introduction 3 With wind tower projects in the UK rapidly increasing the challenge for the UK wind industry is to facilitate development of alternative solutions to ease pressure on the supply chain and drive down costs. Concrete can assist with this challenge. The benets of concrete 4 Concrete is an ideal material in the construction of tall, strong, sophisticated wind farm structures, for onshore or offshore deployment, in aggressive marine or remote inland environments requiring durable materials and details as a matter of course. Onshore solutions 6 Concrete gravity bases provide an ideal solution when constructing the foundations of onshore wind farms. New UK offshore wind zones 6 A variety of concrete gravity base solutions currently under development are well placed to meet the needs of the approximately 7,700 wind energy pylons commissioned through Round 3 development zones and Scottish Territorial Waters development licences. Concrete foundation solutions GBF (Gifford/BMT/Freyssinet) 7 Arup/Costain/Hochtief 8 DTI 50 design concept 9 Consolis Hormifuste 9 Vertax 10 Xanthus Energy 10 Construction requirements 11 To minimise costs, the construction process for gravity bases must be simplied and achieve high repeatability; a challenge well within the scope and potential of concrete construction. Summary 11 Concrete offers a variety of durable, sustainable and economic solutions for wind towers and foundations, and is easily adaptable to meet specic wind farm requirements. Foreword There is no prescriptive plan for the development of a wind farm, whether onshore or offshore. Each prospective site is unique, with its own mix of physical, economic and access constraints. This document demonstrates the key role concrete can play in realising cost-efcient, sustainable and constructible energy converters; addressing the major issues relevant to any onshore or offshore wind farm development. Concrete is uniquely adaptable in terms of performance, design and constructability, making it the material of choice for wind tower foundations and a viable option for the towers themselves. 2 3 Concrete Solutions for Wind Tower Foundations Introduction The provision of wind energy from both onshore and offshore sources is fundamental in enabling the UK to meet its commitment of providing 15 per cent of energy from renewable sources by 2020. This target is a seven-fold increase in renewable energy from the 2008 level. In order to play its part in meeting this renewable energy target, set under the EU Renewable Energy Directive, the UK wind industry is growing at an unprecedented rate. The recent announcement of Round 3 development zones has conrmed the UKs commitment to the target, and will provide the construction industry with over 100 billion of new work. For this offshore development, many of the prime sites in shallow water have already been used so deeper sites further from the shore will become more common. The next 10 years will witness the delivery of the largest ever programme of wind farm development in the UK. This rapid growth in the market will require the development of alternative foundation solutions which by necessity have to be both economic and deliverable in a challenging environment. The challenge for the UK wind industry is to facilitate development of new solutions to ease pressure on the supply chain, while also developing different methods of working to drive down costs. Turbine technology has advanced rapidly to offer turbines with a capacity up to 5 MW, while 10 MW units are under development. To accommodate these ever larger turbines, the towers need to be taller and more robust than previously required. Concrete gravity bases meet all the requirements, and are increasingly considered by developers and contractors as an economic solution for wind farm developments. This brochure sets out the benets of utilising concrete gravity bases for wind farm construction, and also provides an overview of several proposed solutions. This brochure serves as an accompanying document to Concrete Towers for Onshore and Offshore Wind Farms, published in partnership with Gifford in 2007. The original document presented ideas and issues related to the deployment of concrete towers and associated structures, and highlighted a real opportunity for the future of concrete in the wind energy market; then a conceptual view but now coming to fruition. Work has advanced since the 2007 publication, with a number of examples following in this document. Please refer to the References section (page 11) for more information. 1 2 3 4 5 6 7 8 9 Round 3 Sites 1. MORAY FIRTH Moray Offshore Renewables (EDP Renovaveis, SeaEnergy Renewables) 2. FIRTH OF FORTH SeaGreen Wind Energy (SSE Renewables, Fluor) 3. DOGGER BANK Forewind Ltd (SSE Renewables, RWE Npower Renewables, Statoil, Statkraft) 4. HORNSEA SMart Wind Limited (Mainstream Renewable Power, Siemens Project Ventures) 5. NORFOLK BANK East Anglia Offshore Wind (Scottish Power Renewables, Vattenfall Vindkraft) 6. SOUTHERN ARRAY (FORMERLY HASTINGS) Eon Climate and Renewables, UK Southern Array Ltd (Eon Climate, Renewables UK Developments) 7. WEST ISLE OF WIGHT Eneco Round 3 Development Ltd (Eneco New Energy) 8. BRISTOL CHANNEL Bristol Channel Zone Ltd (RWE Npower Renewables) 9. IRISH SEA Centrica Energy Renewable Investments Ltd (Centrica) For wind farm sites in Scottish Territorial Waters, see page 6. 4 Concrete Solutions for Wind Tower Foundations The benets of concrete for wind energy foundations and pylons The wind industrys identied need for increased turbine sizes, rotor diameters and tower heights makes concrete a competitive option. Concretes versatility enables design solutions unlimited by height or size to meet challenges from site conditions and accessibility constraints. It will permit favoured construction methods to be used together with specialist production techniques. Low maintenance Concrete is an inherently durable material, capable of maintaining its desired engineering properties under conditions of extreme exposure. Concretes constituent materials can be easily tailored to economically provide different degrees of durability depending on exposure, environment and further desired properties. Overall durability can be ensured by placing more sensitive structural elements such as prestressing strands in protective sheaths or, if external to the concrete, inside the pylon. With design lives for offshore wind farms in particular on the increase, concretes inherent durability leads to reliability; resulting in wind towers with minimal maintenance requirements throughout their service life. Design and construction exibility Wind farm developers require maximum power output from their sites, which can be achieved using higher-output turbines operating at heights in excess of 100m. Concretes versatility enables design solutions, unlimited by height or size, to meet challenges from site conditions and accessibility to favoured construction methods and availability of specialised production. Efciency can be realised by optimising either in-situ or precast concrete construction methods. High quality sections can be precast in factories under controlled conditions and transported to site in units limited only by size and weight. Simple jointing details are easily achievable with precast concrete units, leading to cost-effective formwork solutions and fast and efcient construction. In-situ concreting takes advantage of proven construction techniques and formwork solutions to deliver quality and efciency. Any initial investment in formwork will be offset through its multiple uses over long production runs, giving lower unit costs. Concrete can be supplied by established ready-mix suppliers who have a track record of controlled supply from well-understood materials or alternatively from on-site mixing. With a state-of-the-art mobile onsite mixing plant, in-situ construction can easily overcome transportation issues associated with more remote sites. Material exibility Concrete is an adaptable construction material, which can be nely tuned through alterations in mix design to optimise parameters such as strength, stiffness, density and heat generation during curing. Recent concrete technological advancements, including the use of chemical admixtures and alternative reinforcement options, allow the production of very high strength, stiff, light-weight and corrosion-resistant solutions. A study [1] into carbon bre reinforced polymers (CFRP) showed that in view of enhanced material properties and reduced concrete cover requirements, the weight of a concrete wind tower prestressed with CFRP would be about 40 per cent lower than that of an equivalent steel prestressed structure. As such, the range of diameters and thickness of sections available to concrete wind tower designers is much greater than when working with other materials; allowing a wider range of solutions and adaptable construction methods. Availability of concrete constituents Concrete is the most widely used construction material. It is a local material and readily available throughout the UK. Existing production facilities will either already be established near the yard where the gravity bases are to be pre-constructed or could be positioned adjacent to the works with the minimum of lead time. This approach will minimise the need for transportation of materials to the construction site, with the associated reduction in environmental, economic and social impact. Localised production will provide jobs for the community and support the local economy. Dynamic performance As concrete has inherently higher damping properties than other materials, solutions with less noise and vibration are deliverable [2]. This is benecial in terms of not only structural demands such as fatigue failure but also public acceptance issues in relation to noise emissions. Use of concrete for pylons, foundations or both can generate considerable advantages, offering design solutions potentially more tolerant of occasional resonance and with a reduced risk of dynamic problems. For tall offshore wind towers, for example, the use of concrete gravity foundations instead of monopiles can offer improvements in dynamic response. For wind tower pylons, prestressed concrete offers high fatigue resistance, providing more tolerance and less risk from dynamic failure. As concrete can accommodate dimensional changes relatively easily, designs can be adapted to larger diameters to economically produce stronger, stiffer towers and avoid transport problems. 5 Concrete Solutions for Wind Tower Foundations Whole life performance Concrete can offer cost-effective wind tower solutions. Conceptual designs and cost studies undertaken by independent consulting engineers [3] indicate that by taking full advantage of concrete technology and adaptable design and construction opportunities, signicant cost savings can be achieved for wind farm developments. For tall towers in particular, concrete can deliver large diameter, low-maintenance pylons with lower relative grid-connection costs with the capability of generating increased levels of power. With relatively short lead-in times for concreting works, construction programme savings can be achieved. Sustainable credentials The fundamental objective of operating wind turbines is to reduce CO 2 emissions and contribute generally to a more sustainable future. Concretes environmental credentials are excellent, with optimisation possible through conservation of materials, the use of waste, cement additions, admixtures and recycled aggregates all with no detrimental impact on structural performance [4]. Responsibly-sourced concrete improves the economic, environmental and ethical standards throughout the supply chain. Clients are now seeking a level of trust in products which goes beyond safety and quality. Concrete which can be manufactured locally using readily-available materials and resources also reduces transportation costs, a key environmental consideration with signicant social and economic impacts. Estimates proposed by independent consulting engineers [5] have shown that - compared to tubular steel - for a typical 70m onshore wind tower conguration, concrete pylon designs can deliver signicant improvements in embodied energy and embodied CO 2 . Due to the excellent sustainability credentials of concrete and the efciency of the designs the operational time required to offset the amount of energy used to construct the gravity bases is approximately six months. In terms of life-cycle design, precast concrete solutions in particular lend themselves to simple deconstruction steps and techniques. For offshore concrete gravity foundations, the employment of established otation techniques avoid potentially complex decommissioning processes and environmental issues associated with driven monopiles in the sea bed. Reinforced concrete is additionally 100 per cent recyclable, with options including reuse of individual concrete structural units or material crushing to provide what is now an industry-accepted aggregate source. Upgradeable By providing strong, stiff, durable wind tower structures with a prolonged service life, prestressed concrete design solutions offer the option to retrot turbines after their design life of about 20 years expires. Prestressing forces can be easily adapted to cope with increased loading. Around three to four next-generation turbine life cycles could easily be accommodated in this way; thereby avoiding the nancial and environmental costs of reconstruction. To fully realise this potential, the structures would need to match this durability requirement; easily achieved using concrete gravity base foundations and towers. Marine environment Concrete is a highly versatile construction material well suited to the harsh conditions existing in marine environments. Its use in marine engineering has been well proven over many years in a wide variety of coastal protection projects, with concrete used extensively as the material of choice. Concrete foundations for offshore wind energy pylons do not need piling and will provide an economic, durable and sustainable solution which will readily accommodate turbine upgrades when required.
6 Concrete Solutions for Wind Tower Foundations Onshore solutions Concrete gravity bases are the most commonly used solution for the foundations of onshore wind farms, with a proven high-performance track record. New UK offshore wind zones In 2010 the winners of tenders for Round 3 development zones (see page 3) were announced, this followed the award of development licences in Scottish Territorial Waters (see Table 1). The successful bidders for these developments are now taking the development process forward, prior to the commencement of construction. The total renewable energy capacity to be provided is in excess of 38GW, and the resulting construction programme will require the installation of approximately 7,700 wind energy pylons in water depths of up to 60m. The graph below, published by The Crown Estate, shows the foundation depths associated with these development zones. The concrete gravity base solutions highlighted in this document could provide solutions for these development zones. The full range of benets attributable to concrete enables the delivery of durable and robust solutions, able to withstand the most challenging of environments. The material is always readily available local to the construction site, minimising the environmental impact of transport. Concrete construction (both precast or slipformed) can be used for the towers of onshore wind farms. The resultant structure is extremely durable with high damping properties, reducing the impact of noise and minimising vibration. Number of installations required vs. mean water depth Water depth range (from mean sea level) less than 20m 20-25m 25-30m 30-35m 35-40m 40-45m 45-50m 50-55m 55-60m 2000 1800 1600 1400 1200 1000 900 800 400 200 0 N u m b e r
o f
I n s t a l l a t i o n s Bars show the minimum and maximum numbers of installations required within each water depth range The low fgure assumes all 6MW turbines, the high fgure assumes all 3.6MW turbines Foundations Table 1: Wind farms in Scottish Territoral Waters MW capacity Developer Argyll Array 1500 Scottish Power Renewables Bell Rock 700 Airtricity & Flour Beatrice 920 Airtricity & SeaEnergy Forth Array 415 Fred Olsen Renewables Inch Cape 905 Npower & SeaEnergy Islay 680 Airtricity Kintyre 378 Airtricity Neart ne Gaoithe 360 Mainstream Solway Firth 300 E ON Wigtown Bay 280 DONG Energy In-situ slipformed concrete tower. Image courtesy of Bierrum Graph courtesy of The Crown Estate 7 Concrete Solutions for Wind Tower Foundations Concrete foundation solutions Foundations for European offshore wind farms have to date been mostly steel monopiles, whilst concrete gravity base foundations have been widely used in the Baltic. As the new wind farm developments move into more challenging sites in deeper waters, the existing solutions are reaching the limit of their performance. New solutions are needed to meet the challenging requirements of the recently announced offshore wind farms.
These solutions need to be straightforward to install, as well as economic and sustainable. Where possible, existing supply chains should be utilised; this will enable the sector to deliver the numbers of turbine foundations required for the UK government to meet its commitment towards the generation of renewable energy.
The following pages provide a summary of some of the gravity base foundation solutions that have been proposed to meet the requirements of the Governments wind farm programme. GBF proposed foundation solution The integrated solution proposed by Gifford, BMT Nigel Gee and Freyssinet (GBF) avoids many of the supply chain hot spots and inefciencies of traditional construction methods. Offshore operations are minimized and onshore assembly works maximised; improving safety and quality whilst enhancing productivity and surety of delivery, as less of the process is weather-dependent. The solution is suited to a variety of sea bed types; sand, clay and rock, water depths between 15m and 60m and is fully removable upon decommissioning. The GBF integrated solution combines three distinct advantages: Mass production of concrete gravity base foundations. Onshore installation of steel mast segments, nacelle, rotor and blades onto the gravity base. Transportation and positioning of the completed turbine onto the sea bed using a purpose built transport and installation barge (TIB). The foundations will be produced on an industrial scale using a production line technique. A purpose-designed un-manned transport and installation barge (TIB) will be used to transport and install the foundation. The TIB will be towed to the wind farm site, where it will be ballasted to lower the foundation into position on the prepared seabed. Once positioning has been veried, the TIB releases the gravity base, moves away and is re-oated, ready for its return journey back to the quayside. The scour protection can then be placed, the electric cable connected and commissioning of the wind turbine can start. The same TIB would be used for eventual decommissioning of the wind turbine. The GBF system is offered by the three consortium companies of Gifford, BMT Nigel Gee and Freyssinet. This grouping combines the strengths and expertise of Gifford (world renowned consulting engineers) BMT Nigel Gee (International Naval Architects) and Freyssinet (world leading specialist contractor.) The GBF solution has been selected by The Carbon Trust for development within the CT Offshore Wind Accelerator programme. The methods and concepts are protected by international patent applications. Construction process 8 Concrete Solutions for Wind Tower Foundations Arup, Costain, Hochtief proposed foundation solution This solution is a self-installing turbine foundation, which can be mass-produced in a construction facility located at ports to suit rapid deployment to UK wind farms. The key features of this solution are: Reinforced concrete non-piled ballasted gravity structure. Caters for water depths up to 60m. Suits larger turbines (up to 8MW units can be accommodated). Minimises the need for sea-bed preparation by accommodating existing seabed slopes and surface sediments. Incorporates skirt variants to suit seabed soil conditions. Standard designs to enable cost optimisation. Construction/installation process Foundations are self-buoyant for ease of deployment to the wind farm location. Standard tugs (readily available) are required for towing to site. Reduced weather dependency. The gravity base foundation has been developed through a partnership between Hochtief, Costain and Arup, founded on long-term relationships from previous projects, and combines unique capabilities to serve the growing energy sector. Hochtiefs strong marine competence, Costains civil engineering and marine construction experience and Arups offshore marine and concrete structure design expertise are the ideal basis to offer a unique and differentiated solution, fully integrating the design, construction, offshore installation and decommissioning of foundations for offshore wind farms. DEME built solution - Thornton Bank Far Shore Wind Farm, Belgium The rst phase of the Thornton Bank wind farm, which is now complete, comprised six concrete gravity base foundations in an average water depth of 16m - each supporting a 5MW turbine. Construction/installation process The foundations were pre-constructed at a facility on the quayside and then transported to the installation site by barge, prior to being lowered onto a pre-prepared foundation. After nal positioning, the foundation units were ballasted with sand/gravel and the turbine system installed in a single lift onto the foundation. Courtesy of Arup. Courtesy of Dredging International. 9 Concrete Solutions for Wind Tower Foundations DTI 50 design concept Design concept The concept is a concrete gravity based structure for wind turbine foundations. The structural support foundations, turbine tower, nacelle and blades are delivered and installed as one unit by a purpose built installation pontoon. The turbine tower is stowed within the main support column, reducing the overall height by approximately 60 metres, during transit. On site, a otation cylinder built into the base of the turbine tower raises the nacelle and blades to a working height when the main support column is lled with water. The turbine tower is then bolted and grouted to the working platform. By de-watering the main support column, the turbine tower can be lowered, allowing access to the nacelle and blades for maintenance or major repairs. The design is engineered to allow component parts to be manufactured by fabrication yards nationwide before delivery to dedicated assembly yards with good quayside facilities. By spreading the workload nationally, the social and economic problems of large workforces working away from home can be avoided. Advantages of the system: Can support 10 MW turbine in up to 50m water depth. Complete wind tower pre-assembled to eliminate heavy lifting on site and minimise weather dependency. Self-installing foundation minimises seabed preparation. Modular construction enables spread of workload. Foundation built aoat, requiring less land for construction. Consolis Hormifuste proposed foundation solution This solution is formed of precast reinforced concrete components, factory-cast for accuracy and economy with rapid assembly at a port facility to minimise the construction period. The approach represents an innovative design simplifying construction, without the need for large pontoons or cranes at sea. Only standard tug boats are required for the installation process. Construction/installation process The components are cast in a factory and then transported to a coastal construction facility where they are assembled using post-tensioned steel tendons. The completed unit is then transported by barge to its nal location where it is placed over a stone bedding layer on the seabed in water depths of up to 25m.
After lowering onto the seabed, the caisson is lled with ballast and the remainder of the tower together with the turbine and rotor blades is placed on it.
The proposed base structure is 25m in height with a diameter of 6m at the top and 20m at its base. Computer graphic by Architech Animation Studios (UK) Ltd, Inverness. 10 Concrete Solutions for Wind Tower Foundations Vertax proposed wind tower solution Vertax Wind leads a group of major organisations in the UK developing the potential of its patented design of a multi-megawatt vertical axis wind turbine generator. The overall structure from sea bed to the electrical hub is marine concrete with a design life of 50 years. Different seabed interfaces have been developed to accommodate varying geological conditions. These interfaces include a concrete gravity base or a concrete monopile. The solution is applicable to water depths of up to 35m with a concrete gravity foundation. For deeper waters other foundation concepts utilising concrete foundations are under development. Construction/installation process The entire structure (less the seabed interface) is deployed as one completely assembled unit, inclusive of generators and rotor. In order to eliminate any unwanted wind loading on the blades during installation, the blades are collapsed in their nesting position close to the tower.
Xanthus Energy foundation system Sea Breeze is a self-installing buoyant concrete foundation system proposed by Xanthus Energy. The foundation is suitable for offshore wind farms in water depths of up to 60m. Key benets of the system are: Self-buoyant system that enables a completely assembled wind turbine generator to be towed to the offshore site and installed without specialist towing or lifting equipment. Can be manufactured close to the shoreline using local labour and materials under factory controlled conditions. Minimal weather dependency for both manufacture and installation. Patented leveling footpads and built-in scour protection suits virtually all sea bed conditions. 11 Concrete Solutions for Wind Tower Foundations Construction requirements Each of the solutions referred to will require a full assessment of their specic construction requirements and applicability to particular wind farms. To minimise costs, the construction process for gravity bases must be simplied and achieve high repeatability; a challenge well within the scope and potential of concrete construction.
A number of port locations have been identied as potential sites for the construction of gravity base foundations. These potential sites are strategically located around the UK, minimising transportation of the pre-constructed foundations and cutting costs and time. Additionally, a number of port operators are endeavouring to create global offshore wind hubs which would provide a focus for the industry and facilitate the construction of foundations, turbines and blades in a single location. At least four such hubs need to be established to service the needs of the industry. The design criteria for offshore wind energy foundations and towers are extremely demanding. The harsh conditions encountered offshore, together with increasing requirements from turbine manufacturers, need to be taken into consideration in the design of the foundations. Concrete, being an extremely versatile material, is able to meet and exceed these demands; thus enabling designs to be future-proofed and allow turbine upgrades when required. A summary of the design drivers to be considered includes: Ground conditions and water depths. Size of turbines and rotors. Appropriate materials and design details for aggressive marine conditions and storm loadings creating cyclical loading on the tower structure. Fatigue effects due to blade rotation with wave loading. Simplicity in design concept, and economic construction. Minimised weather-dependency during construction and installation. Low maintenance, and ease of decommissioning and eventual removal. Full installation requirements and availability of the required lifting equipment. High repeatability production for maximum economy. Future-proof by allowance for future turbine upgrade. For additional details on the design requirements for an offshore wind energy pylon, refer to The Concrete Centre publication Concrete Towers for Onshore and Offshore Wind Farms Conceptual design studies at www.concretecentre.com/publications. Summary The UK wind industry is demanding cost-effective, robust and durable solutions for the next generation of wind energy foundations and pylons. Overall heights in excess of 100m are required to seat ever more powerful turbines - with capacities of 5MW typical. Concrete is able to provide a variety of economic solutions for these foundations and towers; readily adaptable to meet specic wind farm requirements. References 1. For further information visit the University of Cambridge, Department of Engineering website (www.eng.cam.ac.uk) 2. For further information visit the Mecal website (www.mecal.nl) 3. An Initial Study Into The Feasibility Of Concrete Pylons For Large Offshore Wind Energy Converters, The Concrete Centre, October 2004 4. Concrete Credentials: Sustainability, The Concrete Centre, 2010 5. An Estimate of the Embodied CO2 in Steel and Concrete Wind Turbine Towers, The Concrete Centre, September 2005 All advice or information from MPA -The Concrete Centre is intended only for use in the UK by those who will evaluate the signicance and limitations of its contents and take responsibility for its use and application. No liability (including that for negligence) for any loss resulting from such advice or information is accepted by Mineral Products Association or its subcontractors, suppliers or advisors. Readers should note that the publications from MPA - The Concrete Centre are subject to revision from time to time and should therefore ensure that they are in possession of the latest version. Printed onto 9Lives silk comprising 55% recycled bre with 45% ECF virgin bre. Certied by the Forest Stewardship Council. The Concrete Centre, Riverside House, 4 Meadows Business Park, Station Approach, Blackwater, Camberley, Surrey GU17 9AB
Ref. TCC/02/10 ISBN 978-1-904818-97-7 First published 2010 MPA - The Concrete Centre 2010 The Concrete Centre is part of the Mineral Products Association, the trade association for the aggregates, asphalt, cement, concrete, lime, mortar and silica sand industries. www.mineralproducts.org www.concretecentre.com