This document discusses the localization of Acciona Windpower's precast concrete wind turbine tower technology in South Africa. It details the investment made to upgrade a local precast concrete manufacturer to produce 782 tower segments for Acciona's Gouda Wind Farm. This included factory upgrades, new equipment, and training personnel. The project created 216 local jobs and significantly increased local content. It also helped develop new skills and precast concrete technology capabilities in South Africa. Sustaining this investment could reduce costs and lead times for future projects while retaining these skills in the local industry.
Ärk Global is a specialist in logistics services including heavy-lifting and heavy transport with more than two decades of experience in the industry. We are based in more than 25 locations. Check out our corporate profile to get to know us more!
The corporate profile includes:
- Past/ongoing and future projects
- Our equipment and their current locations
- Our branches across the world
- How to get in touch with us
Having all most 16 years extensive professional experience in Saudi Arabia & Pakistan, in the field of civil Engineering execution supervision of Construction, specialized in Buildings, Roads, Highways, Bridges, , infrastructure projects, and other all the site activities storm water pipe lines, Sewerage drains, utility pipe sleeves Box culverts, manholes, open water storm drains and utility lines carried out by the contractor on site accordance with the drawings and standard specifications in Self-motivated initiative and maintains a high level of energy to handle timely and to successfully complete mega highway and Infra structure project.
Eng. M. El-Shorbagy CV and relater certificates ( project manager - pmp) 8.09 mbMohamed ElShourbagy (PMP)
I am interested in working for world classified companies and joining mega projects to enhance my technical and administrative experiences. Over 15 years’ experience in the civil engineering field. Bachelor of Science in Civil Engineering Technology.Ability to lead team members to reach goals within budget and specified time frames. Results-oriented and efficient at carrying out tasks quickly and accurately. Strong analytical and problem-solving skills. Cooperative, efficient, and resourceful.
Ärk Global is a specialist in logistics services including heavy-lifting and heavy transport with more than two decades of experience in the industry. We are based in more than 25 locations. Check out our corporate profile to get to know us more!
The corporate profile includes:
- Past/ongoing and future projects
- Our equipment and their current locations
- Our branches across the world
- How to get in touch with us
Having all most 16 years extensive professional experience in Saudi Arabia & Pakistan, in the field of civil Engineering execution supervision of Construction, specialized in Buildings, Roads, Highways, Bridges, , infrastructure projects, and other all the site activities storm water pipe lines, Sewerage drains, utility pipe sleeves Box culverts, manholes, open water storm drains and utility lines carried out by the contractor on site accordance with the drawings and standard specifications in Self-motivated initiative and maintains a high level of energy to handle timely and to successfully complete mega highway and Infra structure project.
Eng. M. El-Shorbagy CV and relater certificates ( project manager - pmp) 8.09 mbMohamed ElShourbagy (PMP)
I am interested in working for world classified companies and joining mega projects to enhance my technical and administrative experiences. Over 15 years’ experience in the civil engineering field. Bachelor of Science in Civil Engineering Technology.Ability to lead team members to reach goals within budget and specified time frames. Results-oriented and efficient at carrying out tasks quickly and accurately. Strong analytical and problem-solving skills. Cooperative, efficient, and resourceful.
LITERATURE WORK STUDY OF PRECAST CONCRETE CONNECTIONS IN SEISMICIAEME Publication
Structures made in Precast concrete is increasing in India. The special interest of developing any connections is to be done using commonly used construction materials, such as cast-in-place concrete. This is an investigation of the seismic response on the precast structures due to the beam to column connection behaviour. Earthquake could damage the whole structure if it is not properly designed, especially in high seismic regions.
PROJECT MANAGEMENT PLAN OF WHITE PORTLAND CEMENT PLANT PROJECTSAJJAD KHUDHUR ABBAS
The Project management plan presented here will describe the project manager’s approach and the general responsibilities of the project team. In addition to the project management plan, several other documents will be developed and used to ensure compliance with project requirements as well regulations and industry specific standards. The specific plans will include processes, flow diagrams, responsibility matrices, organizational charts, and other pertinent information to guide the project staff.
the presentation gives a brief description about the architectural and engineering design and the construction methodologies applied and some statistical and engineering data
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Similar to Concrete Towers - a business case for sustained investment_Rev 5 (20)
Concrete Towers - a business case for sustained investment_Rev 5
1. Concrete Towers - a business case for
sustained local investment
CONCRETE GROWTH
concrete materials engineers
Santie Gouws
Specialist Consultant –
Concrete Materials Engineering
Director –
Concrete Growth
2. Concrete Towers – a business
case for sustained investment (I)
CONCRETE GROWTH
concrete materials engineers
8. Acciona Windpower’s Concrete Towers (I)
• Patented precast concrete tower design,
complete with engineering drawings and
manufacturing specifications
• 100m and 120m hub heights available
• Developed in-house and commercialized over
the past 8 years
• Reproduced internationally through use of local
contractors without the need for specialized
labour or equipment
• Rolled out in Spain, Brazil, Mexico, Poland
• Now also in
South Africa
• 250 towers to
date
CONCRETE GROWTH
concrete materials engineers
9. Acciona Windpower’s Concrete Towers (II)
Gouda Wind Farm – South Africa
• 46 towers with 100m hub height
• 5 cylindrical 20m concrete sections per tower
• 2 - 4 precast concrete segments per 20m section
• 17 precast concrete segments per tower
• 782 segments in total from 5 moulds ~ 16 500 m3
• ~ 60t per segment
• Manufactured in CT
• Transported 100 km
to Gouda site
• On site assembly
CONCRETE GROWTH
concrete materials engineers
12. Investment into Localization (I)
Key Local Role Players for Gouda
• Concrete Units (SA) with engineering input from
Windtechnic (Spain) – precast manufacture
• Argent - Megamix - concrete
• RSC and Steeledale - reinforcement
• Afrisam - aggregates
• PPC Cement – cement
• BASF SA - admixture
• Absolute Rigging - transport
• B D Materials – grouting contractor
• Sika SA – grout/epoxy sealant/chord
• Concrete Growth – quality management of
precast manufactureCONCRETE GROWTH
concrete materials engineers
13. CONCRETE GROWTH
concrete materials engineers
Investment into Localization (II)
Precast capability base prior to the project
• Peak production and logistics
management rate ~ 500m3/week
• Under-roof factory ~ 3000m2
• Open-air factory area ~ 10 000m2
• Handling equipment
• 100t gantry crane
• 10t reinforcing gantry
• Production staff ~ 50/month
• Steel reinforcing tensile
strength of 450MPa
• Concrete design strength of
50MPa
• Normal vibrated concrete
14. CONCRETE GROWTH
concrete materials engineers
Investment into Localization (III)
Manufacturing requirements for Gouda
• 10 month manufacturing period ~ peak 650m3/w
• Structural concrete to European Standards
• Steel Reinforcing Tensile Strength 500MPa
• Concrete Design Strength of 75MPa
• Self-compacting concrete, no vibration
• Moulds by AWP,
set up by
contractor
• Dimensional
tolerances
to < 1cm
15. CONCRETE GROWTH
concrete materials engineers
Investment into Localization (IV)
Factory upgrade by Concrete Units
• Additional under roof area ~ 1100m2
• Handling equipment increased
• Two additional 35t gantry cranes
• Additional 16t reinforcing crane
• Time Frame ~ 10 weeks (during project start-up)
• Financial Investment ~
R12 000 000
16. CONCRETE GROWTH
concrete materials engineers
Investment into Localization (V)
Investment into people and technology
• Technology transfer through Acciona
Windpower’s ‘Manufacturing Instructions’
• ‘how to’ manual based on Spanish
conditions, materials, methods
• Learning by doing and ‘localizing’
• High strength self-
compacting concrete
• Vertical Joints
• Measuring of performance
by Acciona’s Quality
Management System
17. Measuring the performance
• Acciona Windpower’s Quality Management
System
Investment into Localization (VI)
CONCRETE GROWTH
concrete materials engineers
18. Benefits realized (I)
CONCRETE GROWTH
concrete materials engineers
Investment into people
• Quality Management System as measurement
tool
Local expenditure on raw materials
782 segments ~ 97 % local content
Manufacture of Segments
Concrete (material) 16 500 m3 R 30 000 000
Reinforcement 2 800 t R 26 000 000
Post tensioning
cable
100 t R 2 000 000
TPA – lifting hooks 6256 nr off R 2 000 000
Metallic ducts 8 300 m R 300 000
Assembly of Segments
Grout 38 t per tower
19. Benefits realized (II)
Jobs created and new skills learnt
(Peak production staff component)
• Engineering component (manufacture)
• 10 persons (4 Spanish)
• Quality management team
• 6 persons
• Total staff component ~ 216 persons
• 48 persons sourced from Gouda
• 25 % of these 48 will be incorporated into
the next project
Learnt to work with high strength self-
compacting concrete
Learnt to work in highly industrialized
precast set-up with strict Quality Control
20. 782 Segments Completed – on time and within budget
Cost and lead-time reductions possible for future wind turbine
tower supply.
Benefits realized (III)
0
100
200
300
400
500
600
700
800
900
0
1
2
3
4
5
6
05-Feb19-Feb05-Mar19-Mar02-Apr16-Apr30-Apr14-May28-May11-Jun 25-Jun 09-Jul 23-Jul 06-Aug20-Aug03-Sep17-Sep01-Oct 15-Oct 29-Oct12-Nov26-Nov10-Dec24-Dec
277 units in 5 months
55 units/month
470 units in 3,75 months
125 units/month
Peak
production rate
650 m3/week
21. Localization of Acciona Windpower’s
Precast Concrete Tower Technology
INPUT
• Low capital investment and short implementation
phase of factory upgrade
• Training through learning by doing and measuring
OUTPUT
Gouda Wind Farm 46 WTG’s, 3MW on concrete towers
97% local content in tower segments
216 jobs created, some permanent
High skills and technology development in local
precast concrete manufacture industry
Potential for future reduction in cost and lead time
Potential for application of new skills back into local
construction industry
Real risk of loosing skills if investment not sustained
Conclusions
