Prefabricated Windmill Foundation with Radial Tensioning
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Solution Overview
Problem
The production of windmill foundations using in-situ concrete is time-consuming and costly, requiring complex logistics and high manual effort, and existing prefabricated concrete element solutions lack a monolithic structure to effectively withstand high static and dynamic loads from modern wind turbines.
Innovation Solution
A foundation comprising prefabricated reinforced concrete elements with a first reinforcement structure of radial tensioning elements and a second reinforcement structure that couples with the first to form a monolithic structure, allowing efficient distribution of forces and increased tensile strength through pre-stressing and interconnection of elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If in-situ concrete is used for foundation production, then the foundation can be produced monolithically, but the construction process becomes time-consuming and costly with complex logistics
Solution Approach 1:
The foundation is divided into multiple prefabricated concrete elements (pedestal segments and rib elements) that can be produced separately in a controlled environment and then assembled on-site. This segmentation enables parallel production, reducing overall construction time while maintaining structural integrity through proper connection design.
Solution Approach 2:
Concrete elements are pre-stressed and reinforced with tensioning elements before assembly. The preliminary installation of reinforcement structures and tensioning elements in the prefabrication plant allows for quality control and reduces on-site construction time, addressing both productivity and structural stability requirements.
2Productivity
If prefabricated concrete elements are used for foundation production, then construction time is reduced, but the structure lacks monolithic integrity to withstand high loads
Solution Approach 1:
Multiple prefabricated concrete elements are connected through reinforcement structures and tensioning elements that merge them into a unified load-bearing system. The connection design ensures that the assembled foundation behaves as a monolithic structure, distributing and withstanding high static and dynamic loads from modern wind turbines.
Solution Approach 2:
The foundation combines prefabricated concrete elements with embedded reinforcement structures and tensioning elements to create a composite system. This composite construction provides both the construction speed advantages of prefabrication and the load-bearing capacity of a monolithic reinforced concrete structure.
3Manufacturing precision
If prefabricated concrete elements are used, then production quality can be improved through controlled environment manufacturing, but the elements require complex connection structures to form a unified foundation
Solution Approach 1:
The foundation is segmented into standardized prefabricated elements with integrated connection features. This segmentation allows for precise manufacturing in controlled environments while the standardized connection interfaces simplify the assembly process, reducing overall system complexity despite the modular approach.
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
The solution reduces construction time and costs while enhancing the foundation's ability to withstand high static and dynamic loads, mimicking a monolithic structure for improved durability and resistance.
Implementation Method 1
a first reinforcement structure, which comprises radial tensioning elements for stressing the prefabricated concrete elements
Implementation Method 2
a second reinforcement structure is provided, which holds the prefabricated concrete elements together and is coupled with the first reinforcement structure
Data Source
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AI summary
In a foundation for a windmill with a circular or polygonal pedestal for supporting a windmill tower and a plurality of ribs, which project radially outwards from the pedestal, the pedestal is divided into a plurality of circumferential portions, wherein a circumferential portion and a rib are each formed by at least one prefabricated concrete element, respectively, and wherein the prefabricated concrete elements are made of reinforced concrete, which comprises a first reinforcement structure, which comprises radial tensioning elements, in particular tension rods or tensioning strands, for stressing the prefabricated concrete elements. A second reinforcement structure is also provided, which holds the circumferential portions together and is coupled with the first reinforcement structure, in particular the radial tensioning elements.