5. • SA economic development depends on
• Electricity supply
• Job creation
• IRP 2010 to 2030
• 55 000 MW to be installed in next 20 years
• Up to 9 200 MW wind energy through REIPPP
• 2,5 to 3MW turbines - > 3000 tower structures
• Tower structure ~ 15 % of capital cost of wind farm
• Round 3 Local content requirements:
→ increased to threshold of 40%, target of 65%
• Concrete towers, relatively new technology internationally,
but obvious contender for local contentCONCRETE GROWTH
concrete materials engineers
Wind Energy in South Africa (I)
7. CONCRETE GROWTH
concrete materials engineers
Wind Energy in South Africa (III)
Cost of Energy vs Hub Height
CSIR,
Greene &
E-Science
Associates
8. CONCRETE GROWTH
concrete materials engineers
Wind Energy in South Africa (IV)
Job creation – impact of 50MW wind farm
446
525
525
346
368
368
250
266
266
836
1 380
1 746
691
1 080
1 441
679
902
1 267
1 052
1 350
1 630
796
997
1 272
669
784
1 063
- 1 000 2 000 3 000 4 000
120m Imported steel tower
120m Concrete tower
100m Imported steel tower
100m Concrete tower
80m Imported steel tower
80m Concrete tower
Number of Full Time Equivalent jobs
Direct impact
Indirect impact
Induced impact
CSIR, Greene &
Urban-Econ
Development
Economists
CONCRETE GROWTH
concrete materials engineers
9. CONCRETE GROWTH
concrete materials engineers
Acciona Windpower (I)
International Footprint
Canada 45 MW
USA 704 MW
Mexico 555 MW
France 39 MW
Spain 1,607 MW
UK 32 MW Poland 120 MW
Greece 6 MW
Italy 68 MW
South Korea 68 MW
Australia 239 MW
Chile 60 MW
China 249 MW
10. CONCRETE GROWTH
concrete materials engineers
Acciona Windpower (II)
South Africa
Canada 120 MW
USA 6 MW
Mexico 258 MW
Spain 99 MW
Poland 33 MW
Brasil 330 MW
Chile 45 MW South Africa 148 MW
AW 3000 Orders and Commitments (2013)
14. Acciona Windpower (VI)
CONCRETE GROWTH
concrete materials engineers
AWP Wind Farm in Spain
DESIGNED FOR RE-PRODUCTION
STRONG QUALITY CONTROL SYSTEM
15. GOUDA WIND FARM
• 46 x 3 MW WTG’s
• 100 m high concrete tower support
structures
• Assembled from 5 by 20m cylindrical
pre-assembled units
• Final assembly onto in situ foundation
and post-tensioned
• 17 individual segments/tower
Reproduction of AWP towers as
done elsewhere in the worldCONCRETE GROWTH
concrete materials engineers
Acciona Windpower (VII)
16. GOUDA WIND FARM
• Individual concrete segments manufactured by
Concrete Units in Cape Town for the 1st time,
transported to Gouda
• 782 segments cast from 5 re-usable moulds
• Each segment weighs
60 tonnes
• 9 months of
precasting
Strong AWP Quality
Control System
CONCRETE GROWTH
concrete materials engineers
Acciona Windpower (IIX)
17. • Semi-circular, tapered concrete element
• Building-blocks of concrete towers
CONCRETE GROWTH
concrete materials engineers
Keystones - building blocks (I)
20m
18. • Keystones at Concrete Units Factory in CT
CONCRETE GROWTH
concrete materials engineers
Keystones – building blocks (II)
19. • Top & Bottom of Keystones, horizontal joints
CONCRETE GROWTH
concrete materials engineers
Keystones – building blocks (III)
24. • Concrete Batching
• Batching plant & ready-mixed concrete trucks
• Mould Set-up
• 5 moulds for 782 keystones, re-used daily
• Keystones are cast horizontally
• Mould has bottom section and lid
• Reinforcement and Fixtures
• 1 reinforcement design for keystones of each level
• Fixtures differ per keystone per level, depending on
position in tower
• Concrete Casting
• Self-compacting concrete pumped into moulds
• Curing and Demoulding
• Thermal curing up to required strength
• Demould 1 day after casting
• Final Finishing
• On temporary support structure - horizontallyCONCRETE GROWTH
concrete materials engineers
Keystone Manufacture (I)
34. Top after Final Finishing
CONCRETE GROWTH
concrete materials engineers
Keystone Manufacture (XI)
35. TO ENSURE ‘QUALITY’:
WHICH ASPECTS DO WE WANT TO
CONTROL AND WHY?
• Structural Design Requirements
• Production Requirements
• Functional Requirements for Tower
Assembly and use in Tower
CONCRETE GROWTH
concrete materials engineers
Aspects to Control (I)
36. Structural Design
CONCRETE GROWTH
concrete materials engineers
Aspects to Control (II)
DIMENSIONS
INPUT REQUIRED OUTPUT
MOULD DIMENSIONS GEOMETRY of KEYSTONES
MOULD DESIGN TOWER GEOMETRY
CONCRETE MATERIAL PROPERTIES
INPUT REQUIRED OUTPUT
RAW MATERIALS COMPRESSIVE STRENGTH
PROPORTIONS of RAW
MATERIALS
COMPACTION
TIME of MIXING
TEMPERATURE
37. Structural Design
CONCRETE GROWTH
concrete materials engineers
Aspects to Control (III)
REINFORCEMENT & POST TENSIONING
INPUT REQUIRED OUTPUT
RAW MATERIALS LOAD BEARING CAPACITY
SHAPE AND SIZE - KEYSTONES during
PRODUCTION PROCESSES
POSITION - FINAL TOWER
COVER TO REINFORCEMENT
INPUT REQUIRED OUTPUT
COVER DEPTH DURABILITY
LIMITS ON CRACKS
38. Structural Design
CONCRETE GROWTH
concrete materials engineers
Aspects to Control (IV)
JOINTS BETWEEN KEYSTONES
INPUT REQUIRED OUTPUT
GEOMETRY OF VERTICAL
JOINTS
VERTICAL STRUCTURAL
CONNECTION
VERTICAL JOINT REBAR
GEOMETRY OF TOP &
BOTTOM OF KEYSTONE
HORIZONTAL STRUCTURAL
CONNECTION
REBAR POSITION
REBAR LENGTH
REBAR STRAIGHTNESS
DUCT DIMENSIONS & LENGTH
39. Functional Requirements
CONCRETE GROWTH
concrete materials engineers
Aspects to Control (V)
PRE-ASSEMBLY FIXTURES
INPUT REQUIRED OUTPUT
ANCHOR BOLT CONNECTION
INSERTS PROPERTIES AND
POSITIONS
KEYSTONE POSITIONING
during PRE-ASSEMBLY
DUCT DIMENSIONS KEYSTONE POSITION AND
LEVEL IN TOWER for TOWER
GEOMETRY
BOLT CONNECTION INSERTS
PROPERTIES AND POSITIONS
WORKING PLATFORMS
44. Manufacturing Requirements
CONCRETE GROWTH
concrete materials engineers
Aspects to Control (X)
MOULDS
INPUT REQUIRED OUTPUT
FLOWABILITY OF CONCRETE MOULD DESIGN FOR
HORIZONTAL CASTING
DEMOULDING STRENGTH MOULD TURN-AROUND TIME
THERMAL CURING
SUPPORTS AFTER DEMOULDING
INPUT REQUIRED OUTPUT
DEMOULDING STRENGTH BE ABLE TO BE SUPPORTED
ON TWO POINTS ONLY AFTER
DEMOULDING
45. CONCRETE GROWTH
concrete materials engineers
Quality System Overview (I)
• Engineering Specification & Design
• Functional Design and Structural Design by AWP Engineering
• Based on International Structural Design Code – Eurocode
• Captured in Engineering Drawings and Project Specifications
• Comparison with SANS and Adaption of Specification where Relevant
• Instructions
• Documents describing how each action shall be performed in order to meet
the Engineering Design and Specifications
• Inspection Sheets
• Documents filled in throughout each step of the process documenting the
procedures followed
• Quality Teams
• Contractor – Responsible for Manufacturing according to the quality
specifications; and for documenting their procedures according to the
Quality System
• AWP Quality Team – Inspection of actual processes and checking of
documentation to ensure processes were correctly followed; coordination
with AWP Engineering team where specifications not clear or where
deviations are required for practical, local reasons
46. CONCRETE GROWTH
concrete materials engineers
Quality System Overview (II)
• Traceability
• From Raw Material to Keystone throughout all Processes
• Tolerances
• +/-
• There are no ABSOLUTES
• In line with Engineering Design & Functional Requirements
• Practically Achievable at Related Cost
• Frequency of Measurement
• Initial Production
• Serial Production
• Differs per material type depending on inherent variability & application
Entire process is broken down into individual steps and each is
checked and documented against fixed, repetitive, easy-to-
check criteria
48. CONCRETE GROWTH
concrete materials engineers
Quality System Overview (IV)
SPECIFY MEASURE
&
RECORD
DESIGN
CORRECT
CANNOT
CORRECT
ok
production
deviation
specification
deviation
not ok
56. Inspection Sheets - Concrete
• FLOW TEST FOR
SE SELF-COMPACTING
C CONCRETE
R RECORDED ON SHEET
CONCRETE GROWTH
concrete materials engineers
Quality System
South African government is under pressure in several, but specifically two areas, i.e.
to reduce rate of unemployment and
to increase the country’s electricity supply capacity.
To address these the government’s Integrated Resource Plan, projected that an increase in electricity supply of around 55 000 MW will need to be established within the next 20 years.
A significant component of this plan is the use of renewable energy sources and involvement of Independent Power Producers in these projects with the share of wind energy comprising 9 200 MW as I’ve mentioned before.
To increase the positive effects on the national and local economies that can be derived from this roll-out, the DTI has increased the local content requirements from the 3rd bid submission onwards
to a threshold of 40% and a target value of 65%
with specific reference to local construction of towers,
This is because the tower alone, excluding foundations and civil works making up around 15 to 20% of the capital cost of a windfarm.
South African government is under pressure in several, but specifically two areas, i.e.
to reduce rate of unemployment and
to increase the country’s electricity supply capacity.
To address these the government’s Integrated Resource Plan, projected that an increase in electricity supply of around 55 000 MW will need to be established within the next 20 years.
A significant component of this plan is the use of renewable energy sources and involvement of Independent Power Producers in these projects with the share of wind energy comprising 9 200 MW as I’ve mentioned before.
To increase the positive effects on the national and local economies that can be derived from this roll-out, the DTI has increased the local content requirements from the 3rd bid submission onwards
to a threshold of 40% and a target value of 65%
with specific reference to local construction of towers,
This is because the tower alone, excluding foundations and civil works making up around 15 to 20% of the capital cost of a windfarm.
South African government is under pressure in several, but specifically two areas, i.e.
to reduce rate of unemployment and
to increase the country’s electricity supply capacity.
To address these the government’s Integrated Resource Plan, projected that an increase in electricity supply of around 55 000 MW will need to be established within the next 20 years.
A significant component of this plan is the use of renewable energy sources and involvement of Independent Power Producers in these projects with the share of wind energy comprising 9 200 MW as I’ve mentioned before.
To increase the positive effects on the national and local economies that can be derived from this roll-out, the DTI has increased the local content requirements from the 3rd bid submission onwards
to a threshold of 40% and a target value of 65%
with specific reference to local construction of towers,
This is because the tower alone, excluding foundations and civil works making up around 15 to 20% of the capital cost of a windfarm.
South African government is under pressure in several, but specifically two areas, i.e.
to reduce rate of unemployment and
to increase the country’s electricity supply capacity.
To address these the government’s Integrated Resource Plan, projected that an increase in electricity supply of around 55 000 MW will need to be established within the next 20 years.
A significant component of this plan is the use of renewable energy sources and involvement of Independent Power Producers in these projects with the share of wind energy comprising 9 200 MW as I’ve mentioned before.
To increase the positive effects on the national and local economies that can be derived from this roll-out, the DTI has increased the local content requirements from the 3rd bid submission onwards
to a threshold of 40% and a target value of 65%
with specific reference to local construction of towers,
This is because the tower alone, excluding foundations and civil works making up around 15 to 20% of the capital cost of a windfarm.
Acciona Windpower is currently constructing the Gouda Windfarm, the first in South Africa in which concrete towers will be used. To summarize as follows:
46 precast tower structures will be constructed for the Windfarm
Each tower structure will be 100 m high consisting of 5 times 20m long tapered cylindrical units, all in all made up of 17 segments/ structure
The segments are manufactured at Airport Industria Cape Town, and transported to Gouda site (100 odd km) and assembled and post-tensioned onto in situ foundations
Acciona Windpower is currently constructing the Gouda Windfarm, the first in South Africa in which concrete towers will be used. To summarize as follows:
46 precast tower structures will be constructed for the Windfarm
Each tower structure will be 100 m high consisting of 5 times 20m long tapered cylindrical units, all in all made up of 17 segments/ structure
The segments are manufactured at Airport Industria Cape Town, and transported to Gouda site (100 odd km) and assembled and post-tensioned onto in situ foundations
Acciona Windpower is currently constructing the Gouda Windfarm, the first in South Africa in which concrete towers will be used. To summarize as follows:
46 precast tower structures will be constructed for the Windfarm
Each tower structure will be 100 m high consisting of 5 times 20m long tapered cylindrical units, all in all made up of 17 segments/ structure
The segments are manufactured at Airport Industria Cape Town, and transported to Gouda site (100 odd km) and assembled and post-tensioned onto in situ foundations
This gives an overview of the transport and assembly
To construct one 100m tall tower, 17 tapered concrete segments are manufactured in a typical precast factory,
each segment 20 m in length, and shipped to the windfarm.
During the pre-assembly phase,
the four segments that form the bottom 20m of the tower are placed into position one by one onto the in situ cast concrete foundation,
and the vertical joints grouted tight
The remaining segments are pre-assembled into 4 more 20m long cylinders, each cylinder consisting out of 2 to 4 segments, and the vertical joints grouted tight
During final assembly the remaining 4 cylinders are assembled one on top of the other along with the nacelle and blades
Finally the horizontal joints are grouted, and the five cylinders post-tensioned onto the foundation to complete the assembly.
This gives an overview of the transport and assembly
To construct one 100m tall tower, 17 tapered concrete segments are manufactured in a typical precast factory,
each segment 20 m in length, and shipped to the windfarm.
During the pre-assembly phase,
the four segments that form the bottom 20m of the tower are placed into position one by one onto the in situ cast concrete foundation,
and the vertical joints grouted tight
The remaining segments are pre-assembled into 4 more 20m long cylinders, each cylinder consisting out of 2 to 4 segments, and the vertical joints grouted tight
During final assembly the remaining 4 cylinders are assembled one on top of the other along with the nacelle and blades
Finally the horizontal joints are grouted, and the five cylinders post-tensioned onto the foundation to complete the assembly.
Acciona Windpower is currently constructing the Gouda Windfarm, the first in South Africa in which concrete towers will be used. To summarize as follows:
46 precast tower structures will be constructed for the Windfarm
Each tower structure will be 100 m high consisting of 5 times 20m long tapered cylindrical units, all in all made up of 17 segments/ structure
The segments are manufactured at Airport Industria Cape Town, and transported to Gouda site (100 odd km) and assembled and post-tensioned onto in situ foundations
Acciona Windpower is currently constructing the Gouda Windfarm, the first in South Africa in which concrete towers will be used. To summarize as follows:
46 precast tower structures will be constructed for the Windfarm
Each tower structure will be 100 m high consisting of 5 times 20m long tapered cylindrical units, all in all made up of 17 segments/ structure
The segments are manufactured at Airport Industria Cape Town, and transported to Gouda site (100 odd km) and assembled and post-tensioned onto in situ foundations
Acciona Windpower is currently constructing the Gouda Windfarm, the first in South Africa in which concrete towers will be used. To summarize as follows:
46 precast tower structures will be constructed for the Windfarm
Each tower structure will be 100 m high consisting of 5 times 20m long tapered cylindrical units, all in all made up of 17 segments/ structure
The segments are manufactured at Airport Industria Cape Town, and transported to Gouda site (100 odd km) and assembled and post-tensioned onto in situ foundations
South African government is under pressure in several, but specifically two areas, i.e.
to reduce rate of unemployment and
to increase the country’s electricity supply capacity.
To address these the government’s Integrated Resource Plan, projected that an increase in electricity supply of around 55 000 MW will need to be established within the next 20 years.
A significant component of this plan is the use of renewable energy sources and involvement of Independent Power Producers in these projects with the share of wind energy comprising 9 200 MW as I’ve mentioned before.
To increase the positive effects on the national and local economies that can be derived from this roll-out, the DTI has increased the local content requirements from the 3rd bid submission onwards
to a threshold of 40% and a target value of 65%
with specific reference to local construction of towers,
This is because the tower alone, excluding foundations and civil works making up around 15 to 20% of the capital cost of a windfarm.
South African government is under pressure in several, but specifically two areas, i.e.
to reduce rate of unemployment and
to increase the country’s electricity supply capacity.
To address these the government’s Integrated Resource Plan, projected that an increase in electricity supply of around 55 000 MW will need to be established within the next 20 years.
A significant component of this plan is the use of renewable energy sources and involvement of Independent Power Producers in these projects with the share of wind energy comprising 9 200 MW as I’ve mentioned before.
To increase the positive effects on the national and local economies that can be derived from this roll-out, the DTI has increased the local content requirements from the 3rd bid submission onwards
to a threshold of 40% and a target value of 65%
with specific reference to local construction of towers,
This is because the tower alone, excluding foundations and civil works making up around 15 to 20% of the capital cost of a windfarm.
South African government is under pressure in several, but specifically two areas, i.e.
to reduce rate of unemployment and
to increase the country’s electricity supply capacity.
To address these the government’s Integrated Resource Plan, projected that an increase in electricity supply of around 55 000 MW will need to be established within the next 20 years.
A significant component of this plan is the use of renewable energy sources and involvement of Independent Power Producers in these projects with the share of wind energy comprising 9 200 MW as I’ve mentioned before.
To increase the positive effects on the national and local economies that can be derived from this roll-out, the DTI has increased the local content requirements from the 3rd bid submission onwards
to a threshold of 40% and a target value of 65%
with specific reference to local construction of towers,
This is because the tower alone, excluding foundations and civil works making up around 15 to 20% of the capital cost of a windfarm.
South African government is under pressure in several, but specifically two areas, i.e.
to reduce rate of unemployment and
to increase the country’s electricity supply capacity.
To address these the government’s Integrated Resource Plan, projected that an increase in electricity supply of around 55 000 MW will need to be established within the next 20 years.
A significant component of this plan is the use of renewable energy sources and involvement of Independent Power Producers in these projects with the share of wind energy comprising 9 200 MW as I’ve mentioned before.
To increase the positive effects on the national and local economies that can be derived from this roll-out, the DTI has increased the local content requirements from the 3rd bid submission onwards
to a threshold of 40% and a target value of 65%
with specific reference to local construction of towers,
This is because the tower alone, excluding foundations and civil works making up around 15 to 20% of the capital cost of a windfarm.
South African government is under pressure in several, but specifically two areas, i.e.
to reduce rate of unemployment and
to increase the country’s electricity supply capacity.
To address these the government’s Integrated Resource Plan, projected that an increase in electricity supply of around 55 000 MW will need to be established within the next 20 years.
A significant component of this plan is the use of renewable energy sources and involvement of Independent Power Producers in these projects with the share of wind energy comprising 9 200 MW as I’ve mentioned before.
To increase the positive effects on the national and local economies that can be derived from this roll-out, the DTI has increased the local content requirements from the 3rd bid submission onwards
to a threshold of 40% and a target value of 65%
with specific reference to local construction of towers,
This is because the tower alone, excluding foundations and civil works making up around 15 to 20% of the capital cost of a windfarm.
South African government is under pressure in several, but specifically two areas, i.e.
to reduce rate of unemployment and
to increase the country’s electricity supply capacity.
To address these the government’s Integrated Resource Plan, projected that an increase in electricity supply of around 55 000 MW will need to be established within the next 20 years.
A significant component of this plan is the use of renewable energy sources and involvement of Independent Power Producers in these projects with the share of wind energy comprising 9 200 MW as I’ve mentioned before.
To increase the positive effects on the national and local economies that can be derived from this roll-out, the DTI has increased the local content requirements from the 3rd bid submission onwards
to a threshold of 40% and a target value of 65%
with specific reference to local construction of towers,
This is because the tower alone, excluding foundations and civil works making up around 15 to 20% of the capital cost of a windfarm.
Acciona Windpower is currently constructing the Gouda Windfarm, the first in South Africa in which concrete towers will be used. To summarize as follows:
46 precast tower structures will be constructed for the Windfarm
Each tower structure will be 100 m high consisting of 5 times 20m long tapered cylindrical units, all in all made up of 17 segments/ structure
The segments are manufactured at Airport Industria Cape Town, and transported to Gouda site (100 odd km) and assembled and post-tensioned onto in situ foundations
South African government is under pressure in several, but specifically two areas, i.e.
to reduce rate of unemployment and
to increase the country’s electricity supply capacity.
To address these the government’s Integrated Resource Plan, projected that an increase in electricity supply of around 55 000 MW will need to be established within the next 20 years.
A significant component of this plan is the use of renewable energy sources and involvement of Independent Power Producers in these projects with the share of wind energy comprising 9 200 MW as I’ve mentioned before.
To increase the positive effects on the national and local economies that can be derived from this roll-out, the DTI has increased the local content requirements from the 3rd bid submission onwards
to a threshold of 40% and a target value of 65%
with specific reference to local construction of towers,
This is because the tower alone, excluding foundations and civil works making up around 15 to 20% of the capital cost of a windfarm.
