Spun Concrete Tower Segments with In-Situ Composite Core

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Solution Overview

Problem

The construction of taller and heavier power line towers requires larger segments, which are limited by transport options, leading to increased production and assembly costs due to the need for special joints.

Innovation Solution

The design involves prefabricated spun concrete tower segments that are transported easily and assembled on-site, with a cavity filled with in-situ concrete and prestressing steels to create a composite structure, using a new construction method that includes inclined butt joints and additional reinforcement for cost-effectiveness and ease of assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of stationary object

If tower segments are made larger to achieve taller towers, then the tower height is improved, but the transportability and assembly complexity deteriorate

Engineering Contradiction:

Improvetower heightVSAvoidassembly complexity

Core Design Contradiction:

Length of stationary objectVSDevice complexity

Solution Approach 1:

The tower is divided into multiple segments that can be transported separately and assembled on-site. Each segment is designed with standardized connection elements that simplify the assembly process, allowing taller towers to be constructed without increasing individual segment complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Connection elements are integrated within the segmented structure itself, with nesting features that allow segments to be compacted for transport and then expanded into a stable assembled structure. The connection elements are built into the segments rather than being separate components.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Adaptability or versatility

If special joints are provided for tower segments, then the assembly capability is improved, but the production and assembly costs increase

Engineering Contradiction:

Improveassembly capabilityVSAvoidproduction cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The connection elements are designed as universal components that can be used across different segment types and assembly configurations. A single design of connection element serves multiple functions including alignment, connection, and structural reinforcement, reducing the variety of parts that need to be manufactured.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The connection elements are designed with adjustable parameters such as length, thickness, and connection geometry that can be modified based on specific assembly requirements without changing the basic design. This allows cost-effective production through standardized manufacturing with variable configurations.

Inventive Principle:

Principle #35Parameter changes

3Weight of moving object

If tower segments are made thinner to reduce weight, then the transportability is improved, but the structural strength deteriorates

Engineering Contradiction:

Improvesegment weightVSAvoidstructural strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The tower segments use composite construction combining concrete with reinforcement elements. The thin-walled segments are reinforced with internal steel reinforcement bars and concrete core, creating a composite structure that achieves high strength-to-weight ratio. The combination of materials provides both lightweight properties and structural integrity.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The wall thickness and reinforcement density are varied locally based on structural requirements. Thinner walls are used where possible to reduce weight, while thicker sections and additional reinforcement are applied at critical locations such as connection elements and load-bearing areas to maintain structural strength.

Inventive Principle:

Principle #3Local quality

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 simplifies and reduces the cost of tower assembly by allowing easier transportation and assembly of tower segments, while ensuring structural integrity through compressive forces only, thus addressing the limitations of existing tower construction methods.

Implementation Method 1

An applied prestress ensures that the concrete is subjected to compressive, but not tensile, loads under all operating conditions

Methodology Applied

Scientific EffectPrestress:

Implementation Method 2

the cavity inside the tower segments is at least partially filled with in-situ concrete, resulting in a composite structure consisting of the tower segments made using the spun concrete method and the in-situ concrete that was placed inside

Methodology Applied

Scientific EffectConcrete pouring and setting:

Implementation Method 3

Prestressing steels can be arranged in this cavity, which produce a prestress in the tower segments, which are manufactured using the spun concrete method

Methodology Applied

Scientific EffectCompressive force: Compression

Data Source

PatentEP2963206B1Tower, in particular for power lines

Publication Date: 2017.05.24 EUROPOLES

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AI summary

Tower (1), in particular for power lines, comprising: - a foundation (14); - several tower segments (2, 9, 23) arranged one above the other on the foundation (14) and manufactured using centrifugal concrete construction, enclosing a cavity (7) which, after assembly of the tower segments (2, 9, 23), is partially filled with cast-in-place concrete (6); and - prestressing steels (8) arranged in the remaining cavity (7) to generate prestress.