1. 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, Telf: Fax:

2. 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

3. 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.

4. 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

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

6. 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

7. 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

8. 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

9. 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

10. 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

11. 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

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

13. 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

14. 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

15. 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

16. 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

17. 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

18. 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 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.

19. 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

20. 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

21. 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)

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

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

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

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

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

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

28. 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)

29. 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

30. Precast concrete wind towers
Juan Carlos Arroyo
UPM
TG 6.4 FIB

31. Precast concrete wind towers
Juan Carlos Arroyo
UPM
TG 6.4 FIB

32. Precast concrete wind towers
Juan Carlos Arroyo
UPM
TG 6.4 FIB

33. Precast concrete wind towers
Juan Carlos Arroyo
UPM
TG 6.4 FIB

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

35. 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

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

37. 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

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

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

40. 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

42. Precast concrete wind towers
Juan Carlos Arroyo
UPM
TG 6.4 FIB

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

44. Precast concrete wind towers
Juan Carlos Arroyo
UPM
TG 6.4 FIB

45. 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, Telf: Fax: