Offshore and onshore wind farm development Concrete Solutions for Wind Tower Foundations
Dec 27, 2015
Offshore and onshore wind farm development
Concrete Solutions for Wind Tower Foundations
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Concrete Solutions for Wind Tower Foundations
ContentsIntroduction 3With 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.
Thebenefitsofconcrete 4Concrete 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.
Onshoresolutions 6Concrete gravity bases provide an ideal solution when
constructing the foundations of onshore wind farms.
NewUKoffshorewindzones 6A 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.
ConcretefoundationsolutionsGBF ® (Gifford/BMT/Freyssinet) 7Arup/Costain/Hochtief 8DTI 50 design concept 9Consolis Hormifuste 9Vertax 10 Xanthus Energy 10
Constructionrequirements 11To minimise costs, the construction process for gravity bases
must be simplified and achieve high repeatability; a challenge
well within the scope and potential of concrete construction.
Summary 11Concrete offers a variety of durable, sustainable and economic
solutions for wind towers and foundations, and is easily adaptable
to meet specific wind farm requirements.
ForewordThere 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-efficient,
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.
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Concrete Solutions forWind Tower Foundations
IntroductionTheprovisionofwindenergyfrombothonshoreandoffshoresourcesisfundamentalinenablingtheUKtomeetitscommitmentofproviding15percentofenergyfromrenewablesourcesby2020.Thistargetisaseven-foldincreaseinrenewableenergyfromthe2008level.
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
confi rmed the UK’s 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 benefi ts 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.
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2
3
4
5
67
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Round3Sites1.MORAYFIRTHMoray Offshore Renewables (EDP Renovaveis, SeaEnergy Renewables)
2.FIRTHOFFORTHSeaGreen Wind Energy (SSE Renewables, Fluor)
3.DOGGERBANKForewind Ltd (SSE Renewables, RWE Npower Renewables, Statoil, Statkraft)
4.HORNSEASMart Wind Limited (Mainstream Renewable Power, Siemens Project Ventures)
5.NORFOLKBANKEast Anglia Offshore Wind (Scottish Power Renewables, Vattenfall Vindkraft)
6.SOUTHERNARRAY(FORMERLYHASTINGS)Eon Climate and Renewables, UK Southern Array Ltd (Eon Climate, Renewables UK Developments)
7.WESTISLEOFWIGHTEneco Round 3 Development Ltd (Eneco New Energy)
8.BRISTOLCHANNELBristol Channel Zone Ltd(RWE Npower Renewables)
9.IRISHSEACentrica Energy RenewableInvestments Ltd (Centrica)
For wind farm sites in
Scottish Territorial Waters,
see page 6.
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Concrete Solutions for Wind Tower Foundations
ThebenefitsofconcreteforwindenergyfoundationsandpylonsThewindindustry ’sidentifiedneedforincreasedturbinesizes,rotordiametersandtowerheightsmakesconcreteacompetitiveoption.Concrete’sversatilityenablesdesignsolutionsunlimitedbyheightorsizetomeetchallengesfromsiteconditionsandaccessibilityconstraints.Itwillpermitfavouredconstructionmethodstobeusedtogetherwithspecialistproductiontechniques.
LowmaintenanceConcrete is an inherently durable material, capable of maintaining its
desired engineering properties under conditions of extreme exposure.
Concrete’s 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, concrete’s inherent durability leads to reliability;
resulting in wind towers with minimal maintenance requirements
throughout their service life.
DesignandconstructionflexibilityWind farm developers require maximum power output from their
sites, which can be achieved using higher-output turbines operating at
heights in excess of 100m. Concrete’s 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.
Efficiency 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 efficient construction. In-situ concreting takes advantage
of proven construction techniques and formwork solutions to deliver
quality and efficiency. 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.
MaterialflexibilityConcrete is an adaptable construction material, which can be finely
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 fibre 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.
AvailabilityofconcreteconstituentsConcrete 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.
D ynamicperformanceAs concrete has inherently higher damping properties than other
materials, solutions with less noise and vibration are deliverable [2]. This
is beneficial 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.
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Concrete Solutions for Wind Tower Foundations
WholelifeperformanceConcrete 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, significant 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.
SustainablecredentialsThe fundamental objective of operating wind turbines is to reduce
CO2 emissions and contribute generally to a more sustainable future.
Concrete’s 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 significant 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 configuration, concrete pylon designs can deliver significant
improvements in embodied energy and embodied CO2.
Due to the excellent sustainability credentials of concrete and the efficiency
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 flotation
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.
UpgradeableBy providing strong, stiff, durable wind tower structures with a
prolonged service life, prestressed concrete design solutions offer
the option to retrofit 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 financial 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.
MarineenvironmentConcrete 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.
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Concrete Solutions for Wind Tower Foundations
OnshoresolutionsConcretegravitybasesarethemostcommonlyusedsolutionforthefoundationsofonshorewindfarms,withaprovenhigh-performancetrackrecord.
NewUKoffshorewindzonesIn 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 benefits 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 than20m
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
Num
ber o
f Ins
talla
tion
s
Bars show theminimum andmaximum numbersof installationsrequired within eachwater depth range
The low �gureassumes all 6MWturbines, the high�gure assumes all3.6MW 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
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Concrete Solutions for Wind Tower Foundations
ConcretefoundationsolutionsFoundationsforEuropeanoffshorewindfarmshavetodatebeenmostlysteelmonopiles,whilstconcretegravitybasefoundationshavebeenwidelyusedintheBaltic.
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 Government’s wind farm programme.
GBF®proposedfoundationsolution
The integrated solution proposed by Gifford, BMT Nigel Gee and
Freyssinet (GBF®) avoids many of the supply chain hot spots and
inefficiencies 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 verified, the TIB releases the gravity base,
moves away and is re-floated, 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.
Constructionprocess
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Concrete Solutions for Wind Tower Foundations
Arup,Costain,Hochtiefproposedfoundationsolution
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/installationprocess
� 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.
Hochtief’s strong marine competence, Costain’s civil engineering
and marine construction experience and Arup’s 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.
DEMEbuiltsolution-ThorntonBankFarShoreWindFarm,Belgium
The first 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/installationprocess
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 final 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.
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Concrete Solutions forWind Tower Foundations
DTI50designconcept
Designconcept
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 fl 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 fi 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 afl oat, requiring less land for construction.
ConsolisHormifusteproposedfoundationsolutionThis 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/installationprocess
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 fi 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 fi 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.
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Concrete Solutions for Wind Tower Foundations
VertaxproposedwindtowersolutionVertax 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/installationprocess
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. •
XanthusEnergyfoundationsystemSea 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 benefits 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.
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Concrete Solutions for Wind Tower Foundations
ConstructionrequirementsEachofthesolutionsreferredtowillrequireafullassessmentoftheirspecificconstructionrequirementsandapplicabilitytoparticularwindfarms.
To minimise costs, the construction process for gravity bases must be simplified and achieve high repeatability; a challenge well within the scope and potential of concrete construction. A number of port locations have been identified 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 atwww.concretecentre.com/publications.
SummaryThe 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 specific 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 significance 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.
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