Precast Wind Turbine Foundation with Monolithic Reinforcement
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Solution Overview
Problem
The manufacturing of wind mill foundations using on-site casting of concrete is time-consuming and costly, requiring complex logistics and labor-intensive site operations, and existing precast concrete element solutions lack a monolithic structure to effectively resist high static and dynamic loads from large wind turbines.
Innovation Solution
A wind mill foundation composed of precast reinforced concrete elements with a second reinforcement structure that couples with the first reinforcement structure to form a monolithic load path, using rigid longitudinal reinforcement elements and a jacket to connect precast concrete elements and distribute forces effectively, simulating a monolithic structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If on-site casting of concrete is used for foundation manufacturing, then the foundation can be produced without precast elements, but the process becomes time-consuming and costly with complex logistics and labor-intensive operations
Solution Approach 1:
The patent applies preliminary action by manufacturing foundation components (pedestal and ribs) as precast concrete elements before transport to the installation site. The reinforcement structures are assembled and concrete is cast in controlled factory conditions, allowing curing to begin before the components are even installed on-site, thereby significantly reducing on-site construction time and logistics complexity
Solution Approach 2:
The foundation is segmented into separate precast components (pedestal sections and rib elements) that can be manufactured independently in a factory setting. These segmented components are then transported and assembled on-site, eliminating the need for large-scale on-site formwork and concrete pouring operations, thus reducing both time and logistical requirements
2Loss of time
If precast concrete elements are used to reduce on-site construction time, then construction duration is reduced, but the foundation lacks a monolithic structure to effectively resist high static and dynamic loads
Solution Approach 1:
The patent merges multiple precast concrete elements (pedestal circumferential sections and radial ribs) into a unified monolithic foundation structure through the integration of reinforcement structures. The first reinforcement structure embeds elements within each precast component while the second reinforcement structure connects these components together, creating a continuous load path that behaves as a single monolithic structure, thereby maintaining high load resistance despite the segmented manufacturing approach
Solution Approach 2:
The foundation employs composite construction by combining precast concrete elements with embedded reinforcement structures (steel bars and connecting reinforcement). This composite approach allows the segmented precast components to function together as a unified structural system with monolithic behavior, resisting both static and dynamic loads effectively while retaining the manufacturing advantages of precasting
3Manufacturing precision
If precast concrete elements are manufactured in a controlled plant environment, then quality and curing can be monitored closely, but the elements require complex connection structures to achieve monolithic behavior
Solution Approach 1:
The patent extracts the complex reinforcement assembly operations from the on-site construction process and relocates them to the controlled factory environment. The first reinforcement structure is embedded into each precast element during factory manufacturing, and the second reinforcement structure is pre-assembled for connecting elements on-site. This extraction simplifies on-site operations to primarily assembly and connection tasks, reducing the need for complex on-site formwork and reinforcement installation while maintaining manufacturing precision
Data Source
AI summary
A foundation for a wind mill includes a circular or polygonal pedestal for supporting a wind mill tower and a plurality of ribs radiating radially outwardly from the pedestal, wherein the pedestal is divided into a plurality of circumferential sections, wherein a circumferential section and a rib are each integrally formed with one another as a precast concrete element, wherein the precast concrete elements are made from reinforced concrete including a first reinforcement structure, in particular reinforcement bars, embedded into the precast concrete elements, a second reinforcement structure is provided, which holds the precast concrete elements together and which is coupled to the first reinforcement structure.