Segmented Tower Foundation Precast Structure for Faster On-Site Assembly
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Solution Overview
Problem
Existing foundation construction methods for large structures like wind turbine towers are time-consuming, costly, and require extensive on-site work, limiting accessibility and quality control, while conventional precast elements are impractical due to size and weight.
Innovation Solution
A semi-finished foundation segment comprising precast elements with outer boundary elements and reinforcement struts that extend into an interior space, allowing for a combined cast-in-place and precast construction method, reducing weight and size for efficient transport and installation, and enabling formwork-free construction with high-strength monolithic structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional precast concrete elements are used for foundation construction, then structural integrity is improved, but weight and size increase making transport and installation impractical
Solution Approach 1:
The foundation is divided into multiple precast concrete segments that are assembled on-site. Each segment is of manageable size and weight for transport and installation, while collectively forming a complete foundation structure with continuous reinforcement through overlapping steel strands.
Solution Approach 2:
Precast concrete segments are nested together with overlapping reinforcement strands that extend from one segment into the next, creating a continuous load-bearing path. The segments contain hollow interiors that reduce weight while maintaining structural strength through the concrete shell and reinforcement.
2Adaptability or versatility
If foundations are constructed on-site with extensive formwork and reinforcement work, then adaptability to site conditions is improved, but construction time and costs increase
Solution Approach 1:
Foundation segments are precast off-site with reinforcement and concrete already in place, eliminating the need for extensive on-site formwork and concrete pouring. The segments arrive ready-to-assemble, significantly reducing construction time while allowing site-specific adjustments during assembly.
Solution Approach 2:
Grout is used as an intermediary material to fill gaps and bond the precast segments together, creating a monolithic appearance and ensuring structural continuity. The grout accommodates minor variations in segment dimensions and site conditions while maintaining overall foundation integrity.
3Strength
If heavy precast foundation segments are used, then load-bearing capacity is improved, but transport and installation become impractical
Solution Approach 1:
The foundation is segmented into multiple smaller units that can be transported using standard equipment and assembled on-site. Each segment maintains sufficient load-bearing capacity through optimized concrete sections and reinforcement, while the collective assembly achieves the required overall strength.
Solution Approach 2:
Each precast segment is designed with optimized local geometry and reinforcement distribution to achieve maximum strength-to-weight ratio. The segments have thicker concrete sections where loads are applied and thinner sections where less material is needed, reducing overall weight while maintaining load-bearing capacity.
Data Source
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AI summary
The invention relates to a semi-finished part (200) for a foundation (120) of a tower construction, in particular of a wind turbine tower (100, 102), comprising at least two semi-finished part foundation segments (300), which each have an outer delimitation element (210) and a reinforcement (230), which is connected to the outer delimitation element (210) and comprises struts (321, 322) protruding from the outer delimitation element (210), wherein: the outer delimitation elements (210) of the semi-finished part foundation segments (300) form an outer edge, which delimits an interior to be later filled curable casting material; and the reinforcements (230) of the semi-finished part foundation segments (300) extend from the outer edge into the interior.