Precast Concrete Flange Leveling for Wind Turbine Tower Assembly
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Solution Overview
Problem
In the construction of wind turbine towers using precast concrete parts, manufacturing tolerances lead to uneven flange surfaces, causing load concentration and subsequent damage, such as spalling of concrete, which complicates repairs and results in structural damage and economic losses.
Innovation Solution
A method involving the application of a low-viscosity resin leveling layer to the flange of precast concrete parts during production, allowing for precise alignment and compensation of unevenness, with a formwork unit that ensures a defined cavity is filled with resin to create a consistent leveling layer, avoiding on-site mortar application and reducing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a leveling layer is applied on site during tower erection, then manufacturing tolerances can be compensated, but construction time increases and weather-dependent delays occur
Solution Approach 1:
The leveling layer is applied in the factory before the precast concrete elements are shipped to the construction site. This preliminary action allows the leveling layer to cure under controlled conditions, eliminating weather-dependent delays during tower erection while still compensating for manufacturing tolerances in flange surfaces.
2Manufacturing precision
If a leveling layer is applied on site, then uneven flange surfaces can be compensated, but the process requires careful mixing and application that increases error susceptibility
Solution Approach 1:
The leveling layer is applied in the factory under controlled conditions with proper mixing and application procedures that can be consistently followed. This preliminary action eliminates the risk of improper on-site application while still achieving the required surface flatness compensation.
Solution Approach 2:
The manual mixing and application process on site is replaced by a factory-based system where the leveling layer can be professionally applied and cured under controlled conditions, reducing human error and improving process reliability.
3Ease of manufacture
If conventional concrete construction tolerances (±10mm) are used, then construction is simpler, but load concentration occurs on small surface sections causing spalling damage
Solution Approach 1:
The tolerance parameter for flange surfaces is changed from conventional ±10mm to a tighter tolerance through the application of a leveling layer in the factory. This parameter change ensures that the entire flange surface is sufficiently flat to distribute loads evenly, preventing stress concentrations that would cause spalling damage.
4Adaptability or versatility
If leveling layer material is applied on site, then field adjustments can be made, but health hazards from resin processing increase
Solution Approach 1:
The hazardous resin processing operation is extracted from the construction site and moved to the factory environment. This allows field workers to avoid exposure to resin health hazards while still achieving the necessary field adjustments through the pre-applied leveling layer that can be accommodated to site-specific conditions.
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 enables faster, more accurate, and cost-effective construction of wind turbine towers with improved mechanical properties and reduced health hazards, allowing for precise alignment and compensation of manufacturing tolerances, thus preventing structural damage and enhancing construction efficiency.
Implementation Method 1
a material with low viscosity for a leveling layer is applied to a flange of the precast concrete part
Data Source
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AI summary
The invention relates to a process for producing prefabricated compound tower-segment units (20) for a tower of a wind plant. A formwork (10) is supplied, and the formwork is filled with concrete. A low-viscosity material is applied, in the form of a compensation layer, to a flange of the prefabricated compound unit (20).