Tower Foundation Pipe Segment Grout Connection
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Solution Overview
Problem
Existing methods for founding tower structures, particularly onshore wind turbines, face challenges in creating a simple and effective connection between the tower and the foundation, especially in soft subsoil conditions, where ramming or vibrating piles require expensive flange connections and complex mechanical constructions.
Innovation Solution
A method involving the use of a pipe segment partially filled with a hardenable casting compound, driven into the subsoil alongside foundation piles, forming an annular space that is then filled with the grout, allowing for load transfer without the need for flange connections, using tubular, T, I, or Z-profiles, and supported by brackets for alignment and temporary load transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If driven piles or vibratory piles are used as foundation with flange connections for fastening the tower structure, then the foundation can be securely anchored in soft subsoil, but the connections must be designed to withstand driving or vibrating forces and require complex welding operations afterwards
Solution Approach 1:
The invention extracts the connection element (flange) from the foundation pile, allowing the pile to be driven into the ground without any connection components attached. The flange is instead welded to the tower structure's connection profile, separating the foundation anchoring function from the connection function. This eliminates the complexity of designing connections that must withstand driving forces while maintaining secure anchoring reliability.
Solution Approach 2:
The invention segments the foundation system into two independent components: the driven pile (providing anchoring) and the flange connection (providing tower attachment). The pile is driven first without any attachments, then the flange is separately welded to the tower structure. This segmentation allows each component to be optimized independently, reducing overall system complexity while maintaining reliability.
2Reliability
If flange connections are welded onto foundation piles after driving, then secure connection to the tower structure is achieved, but the welding process becomes relatively complex and time-consuming
Solution Approach 1:
The invention performs the driving action preliminarily, driving the foundation pile into the ground before any connection operations. The pile is driven in its simple, attachment-free state, which speeds up the driving process. The connection operations (welding the flange to the tower structure) are then performed separately on the already-positioned pile, allowing for more efficient construction sequencing and improved overall productivity.
3Reliability
If connections are designed to withstand driving or vibrating forces during pile installation, then the foundation can be securely installed in soft subsoil, but the connection design and construction process becomes more complex
Solution Approach 1:
The invention extracts the connection element from the pile assembly process entirely. The flange connection is designed and manufactured separately as a standalone component that attaches to the tower structure, not as an integrated part of the driven pile. This separation dramatically simplifies both the manufacturing of the connection elements and their installation, while the pile itself can be driven without any special design considerations for withstanding connection forces.
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 method simplifies the connection process by relying solely on the grout for load transfer, eliminating the need for flange connections and mechanical constructions, providing a stable foundation through skin friction between the grout and the pipe segment and foundation pile.
Implementation Method 1
providing a stable foundation through skin friction between the grout and the pipe segment and foundation pile
Implementation Method 2
partially filled with a curable grout
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a method for constructing a foundation for a tower structure (2), comprising at least one structure-side connection profile in the form of a pipe segment (3). The method has the steps of providing a foundation pile (4) with a diameter which differs from the diameter of the pipe segment (3), vibrating and/or ramming the foundation pile (4) into a supporting substratum (1), aligning and fixing the pipe segment (3) coaxially and concentrically to the foundation pile (4) introduced into the substratum such that an annular space (6) is formed between the pipe segment (3) and the foundation pile (4), and filling the annular space (6) with a curable casting compound (8).