Offshore Wind Support Structure Assembly with Localized Grouted Joints

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for assembling offshore wind turbine support structures require significant grout consumption, which increases costs and decreases buoyancy in floating structures, while cast steel shells complicate production and transportation.

Innovation Solution

The method involves interconnecting tubular braces to a tower support using concrete-cast shell units with grouted connections, allowing for reduced grout consumption and simplified production by casting shells near the assembly site, enhancing flexibility and stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If grout is inserted in the entire tubular structure to provide stability, then the degree of stability is improved, but grout consumption increases significantly

Engineering Contradiction:

ImprovestabilityVSAvoidgrout consumption

Core Design Contradiction:

Stability of the object's compositionVSQuantity of substance

Solution Approach 1:

The patent applies local quality by placing shell units only at specific connection points (joints) where braces meet, rather than filling the entire tubular structure with grout. The shell units are positioned at locations requiring structural reinforcement, providing stability locally where needed while avoiding unnecessary grout consumption in other areas.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent segments the grouting process by dividing the structure into discrete connection points and using individual shell units at each joint. This segmentation allows grout to be applied only where structurally necessary, rather than filling the entire continuous tubular structure, thereby reducing overall grout consumption while maintaining stability at critical locations.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If cast steel shells are used for connecting tubes to provide stability, then the degree of stability is improved, but production complexity and transportation costs increase

Engineering Contradiction:

ImprovestabilityVSAvoidproduction complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent replaces expensive, complex cast steel shells with simpler, more economical concrete shell units. These concrete shells are easier to produce and transport, serving as effective connection elements without the manufacturing complexity and cost associated with cast steel shells, while still providing the necessary structural stability.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the material parameter from cast steel to concrete for the shell units. This material substitution reduces production complexity and transportation requirements while maintaining the structural function of providing stable connections between tubular braces. The concrete shells offer a simpler, more cost-effective alternative with adequate mechanical properties for the application.

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If grout is used to fill braces in floating structures, then connection stability is improved, but buoyancy decreases

Engineering Contradiction:

Improveconnection stabilityVSAvoidbuoyancy

Core Design Contradiction:

Stability of the object's compositionVSWeight of moving object

Solution Approach 1:

The patent applies local quality by confining grout to small, localized shell units at connection joints rather than filling entire braces. This localized approach provides necessary connection stability at joint locations while minimizing the volume of grout used, thereby preserving the buoyancy of floating structure components.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses partial action by applying grout only where absolutely necessary for connection stability, rather than excessive filling of entire braces. The shell units contain grout in precise, minimal quantities sufficient for joint reinforcement, avoiding unnecessary weight addition that would reduce buoyancy in floating structures.

Inventive Principle:

Principle #16Partial or excessive action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach minimizes grout usage, reduces material and transportation costs, and provides adjustable and lightweight connections, improving the assembly process and structural integrity of offshore platforms.

Implementation Method 1

filling a volume in the cavity with a hardening fixation material, typically grout, after insertion of the corresponding brace

Methodology Applied

Scientific EffectHardening of fixation material:

Data Source

PatentUS20250215856A1Method for assembling an offshore support structure for a wind turbine

Publication Date: 2025.07.03 STIESDAL OFFSHORE AS

AI summary

In the assembly of an offshore support structure for a wind turbine, tubular braces are interconnected or connected to a tower support in casted connections where an end part of the corresponding brace is inserted into a cavity of a concrete-casted shell unit that is fixed onto the outer surface of the inter-connecting brace or on the outer surface of the tower support, and the volume in the cavity is filled by a hardening fixation material, typically grout, after insertion of the corresponding brace.