Climbing Formwork for Concrete Wind Turbine Towers
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Solution Overview
Problem
The construction of concrete towers for wind turbines is hindered by the need for high and increasingly expensive large-capacity cranes due to the height of the towers, and existing in situ methods are slowed down by frequent changes in formwork geometry, particularly for truncated cone designs.
Innovation Solution
A manufacturing process using a single climbing formwork system to create concrete towers composed of a reduced number of cylindrical sections with minimal formwork changes, allowing for faster construction and optimized material use by limiting diameter variations between sections, thus reducing crane usage and assembly time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a truncated cone-shaped tower is constructed in situ by means of climbing formworks with frequent geometry modifications, then the tower achieves aerodynamic efficiency, but the construction time increases significantly due to the high frequency of formwork changes
Solution Approach 1:
The tower is divided into multiple cylindrical sections with constant outer diameters rather than a continuous truncated cone shape. This segmentation allows the use of a single climbing formwork system for each section, eliminating the need for frequent formwork geometry modifications and significantly reducing construction time while maintaining structural functionality
Solution Approach 2:
The formwork system is designed to be adaptable through a limited number of geometry changes between sections rather than continuous modification. The climbing formwork can be adjusted between different cylindrical section configurations, providing the necessary flexibility to construct varying tower profiles without requiring frequent reconfiguration
2Productivity
If the tower is constructed with a reduced number of cylindrical sections to minimize formwork changes, then the construction time is reduced, but the material consumption increases
Solution Approach 1:
The tower design optimizes the number and dimensions of cylindrical sections by adjusting parameters such as section height, outer diameter variations, and wall thickness. This allows finding an optimal balance where a reduced number of sections minimizes formwork changes and construction time, while the material consumption increase is kept within acceptable limits through careful parameter optimization
3Ease of manufacture
If large-capacity cranes are used for lifting loads during tower construction, then the tower sections can be assembled, but the project cost increases and crane availability is limited
Solution Approach 1:
The tower is segmented into cylindrical sections that can be constructed using a climbing formwork system that climbs as the tower is built. This eliminates the need for large-capacity cranes to lift entire tower sections, as the formwork system supports the construction process incrementally, reducing crane capacity requirements and associated costs
Data Source
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AI summary
A manufacturing process in situ of concrete towers for wind turbines which enables executing a design of concrete tower manufactured in situ by means of climbing formwork, which reduces the execution time of the concrete tower, where the invention also relates to the associated concrete tower for wind turbine.