WIND TOWERS. BIG PICTURE Conference: PRECAST CONCRETE WIND TOWERS. BIG PICTURE Juan Carlos Arroyo Portero MSc Civil engineer CALTER INGENIERÍA Convenor TG 6.4 FIB: Precast concrete wind towers CERTIFICADA EN EL DISEÑO Y CÁLCULO DE PROYECTOS DE ESTRUCTURAS DE OBRA CIVIL Y EDIFICACIÓN DATOS DE CONTACTO. Valenzuela 8, Madrid, 28014. Telf: 91 319 12 00 Fax: 91 319 12 00 Email: jcarroyo@calter.es - www.calter.es

Electricity business’ Agents: Generation Transport Distribution Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Wind market Electricity business’ Agents: Generation Transport Distribution Comercialization

Developpers or Promoters of a wind farm They sell the energy Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Generation Developpers or Promoters of a wind farm They sell the energy They are the final client of a tower But they usually hire a turbine manufacturer that’s the actual client.

Generation (spanish case) Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Generation (spanish case) Energy business Iberdrola Renovables ENEL Green Power (Endesa) E. ON Renovables Other Agents as Promoters / Owners Suppliers or Turbine manufacturers GESTAMP R. GAMESA R. ACCIONA R. Construction companies

Turbine manufacturers (2015) Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Turbine manufacturers (2015)

Turbine manufacturers Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Turbine manufacturers The new 2015 lider GOLDWIND has been succeeded by SIEMENS+GAMESA 2014 lider was VESTAS 8 of 15 are chinese 99% of chinese new turbines has been installed in China Excepting China, the first 5 manufacturers sell the 75% of turbines

Mature countries / types of wind farms Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Mature countries / types of wind farms Europe Little wind farms: No more than 30 WT Between 3 and 12 WT Powerfull turbines > 3,0 MW High towers > 120,0 m Existing concrete plants near location Availability of specialized hand labour, cranes and trucks/roads

Mature countries / types of wind farms Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Mature countries / types of wind farms North of Africa and Middle East Egypt Morocco Market in evolution

Mature countries / types of wind farms Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Mature countries / types of wind farms LATAM Brasil, Mexico Big wind farms: No less than 30 WT Up to 120 WT Turbines < 3,0 MW Medium high towers 100 > 120 m Mobile concrete plants Difficulties to obtain specialized hand labor (cheap), cranes and trucks/roads

Mature countries / types of wind farms Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Mature countries / types of wind farms LATAM Complex policy of taxes Advantages in the use local hand labor Cheap hand labor Prices of raw materials fixed by the State

Mature countries / types of wind farms Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Mature countries / types of wind farms EEUU, Canada Steel towers China Huge market Exclusively local turbines and towers They are looking for european tower’s concrete technolgy to reach >120m India Huge steel market Easier penetration for foreigner companies

Mature countries Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Mature countries

Internals (Cables, Elevator, platforms, ladders) Tower Foundation Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Parts of a tower Blades (Rotor) Nacelle (Turbine) Internals (Cables, Elevator, platforms, ladders) Tower Foundation

Phases of the construction of a tower Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Phases of the construction of a tower Developper Selection of the turbine and type of tower According with Turbine Manufacturer Engineering (Loads / Certification) Prefabrication Transport Erection of Tower / Nacelle / Blades

Types of tower Material Steel Reinforced Concrete Prestessed Concrete Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Types of tower Material Steel Reinforced Concrete Prestessed Concrete

Types of tower Elevation Full material Hybrid Concrete Steel Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Types of tower Elevation Full material Concrete Steel Hybrid concrete + steel

Erection w/cranes first the lower ring Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Types of tower Process In situ Concrete Prefabricated Steel Erection w/cranes first the lower ring Erection w/jacks, frst de upper ring

The steel tower is the most usual solution Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Types of tower Steel The steel tower is the most usual solution Is the best solution up to 80-100 m TM have a catalogue of steel towers for their Turbines. TM owns the engineering solutions TM is a “metalic world” so it s difficult to introduce concrete as a good and technological solution.

In steel towers highers than 100 m: Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Types of tower Steel In steel towers highers than 100 m: Diameter has to be bigger than 3,50 m => Or special transport Or vertical joint, joined on site Or keep the diameter but increase the depth of steel that implies very difficult and expensive bending of plates

Is a competitive solution for heights bigger than 100 m. Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Types of tower Concrete Is a competitive solution for heights bigger than 100 m. Durability of concrete towers are bigger than stell without maintenance The weight and the time for erection are greater than a metallic tower

Precast solution is competitive for wind farms greater than 30. Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Types of tower Concrete Precast solution is competitive for wind farms greater than 30. Best solution in concrete is postensionned concrete Reinforced concrete tower solution wasn't succesfull (they had many probems)

Solutions for Concrete Towers Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Solutions for Concrete Towers Enercon

Max Boegl Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Max Boegl

ACCIONA Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB

Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB CALTER

Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB CALTER

Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB CALTER

Fatigue loads (Markov matrix) Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Process of design Wind Class Geometry, Clearance Diameter on top Loads Fatigue loads (Markov matrix)

Frequencies range. Campbell diagram Fatigue. Markov matrix Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Process of design Frequencies range. Campbell diagram Fatigue. Markov matrix Prestress (to control deformations, crcking and neutral axis) Horizontal joints

Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB

Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB

Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB

Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB

Certification Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Certification

Mobile plants (farm farther than 200 km) Fixed plants Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Prefabrication Mobile plants (farm farther than 200 km) Fixed plants ¡Changes of layout! 20 m pieces 50 ton 2 towers / week (aprox. 60 pieces) Space enough to storage

Prefabrication Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Prefabrication

Transport Not larger than 12 m Not wider than 3,5 m Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Transport Not larger than 12 m Not wider than 3,5 m

Erection Preassemble Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Erection Preassemble

Erection Assemble Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Erection Assemble

3 months to cast enough towers to be erected 2 towers/week Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Time 2 months to implant 3 months to cast enough towers to be erected 2 towers/week

Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB

Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB Prices

Precast concrete wind towers Juan Carlos Arroyo UPM TG 6.4 FIB

THANKS Conference: PRECAST CONCRETE WIND TOWERS. BIG PICTURE Juan Carlos Arroyo Portero MSc Civil engineer CALTER INGENIERÍA Convenor TG 6.4 FIB: Precast concrete wind towers CERTIFICADA EN EL DISEÑO Y CÁLCULO DE PROYECTOS DE ESTRUCTURAS DE OBRA CIVIL Y EDIFICACIÓN DATOS DE CONTACTO. Valenzuela 8, Madrid, 28014. Telf: 91 319 12 00 Fax: 91 319 12 00 Email: jcarroyo@calter.es - www.calter.es