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Sustainable solutions for faster
construction of the higher tower and
             foundation

                           Tech. Dr. Martin Nilsson
                        Luleå University of Technology
Division of Structural and Construction Engineering – Structural Engineering
                           Martin.C.Nilsson@ltu.se
                        Prof., Tech. Dr. Milan Veljkovic
                        Luleå University of Technology
   Division of Engineering and Construction Structural – Steel Structures
                            Milan.Veljkovic@ltu.se
Agenda
•  Introduction, demands on improved competitiveness.
•  The complete assessment: design, environmental and economical
   life cycle assessment.
•  Innovations in foundations.
•  Conclusions.
Future requirements
By year 2020, 30 TWh of the electricity consumption in Sweden
   should be produced by wind power. (Target by Swedish Wind
   Energy).
Wind power plants will be constructed at remote locations, in short
   time and under harsh climate conditions. The plants must have
   good locations, good turbines and be built both quickly and
   competitively
Wind power plants must be designed with sustainable solutions, both
   environmentally and economically.
Turbines have to be built higher than 100 m to gain stable and more
   constant wind.
New demands for competitiveness on wind energy sector
The future requirements impose new demands on costs and
  effectiveness of:
   –  turbine design,
   –  wings, including de-icing where necessary,
   –  bearing structural components – towers and foundations,
      production and assembling for higher towers
Economics of Wind Power
   UK experience

                           On‑shore               Offshore
Element
                        Cost as % of total    Cost as % of total
• Turbine                     • 33%                  • 21%
• Blades                      • 22%                  • 15%
• Tower                       • 20%                  • 13%
• Foundation                   • 9%                  • 21%
• Grid connection              • 6%                  • 21%
• Design & Management         • 10%                  • 9%

• Total cost per MW      • €1.5 - 2 million   • €2.5 – 3.5 million
Existing and alternative tubular steel tower solutions
Existing concrete tower solutions
Prefabricated elements
In-situ cast with slip form




                              1



                              2


                              3
Environmental and economical assessment
Economical and environmental life cycle assessment of an on-shore
wind power structure focusing on embodied equivalent CO2 emissions
and energy consumed in manufacturing, transportation, erection and
dismantling.

Example from Master Thesis by
Josep Pigem Rodeja, LTU:
The mass of CO2
and energy used per
produced kWh at consumers
place for a 100 m high tubular steel
tower and a pre-stressed
concrete tower with foundation
Environmental and economical assessment
   Approximate structural design, equivalent loading
P 1.  Ultimate Limit State (ULS)
       - Enough strength of materials.
       - Instability phenomena.
P 2.  Fatigue Limit State (FLS)
       - Steel: structural details.
       - Concrete: Separately by material
O 3.  Dynamic Stability
       - Vibration behaviour.
       - Avoid resonance problems.
Environmental and economical assessment
                                                Ømin = 3m
Geometrical approach




                                 100 m
              Cross-section



                                         Conical tower
Environmental and economical assessment
Steel tower




Concrete tower
 Østrand = 15.7 mm
 ns = 12
 ntendon = 56
Environmental and economical assessment
Material data
                        Carbon intensity Energy intensity
       Material                                                            Recovery
                          [kg CO2/kg]        [MJ/kg]
      Steel plates           11.78            0.800         11 % reused, 88 % recycled, 1 % landfill
    Reinforcement            12.42            0.870         11 % reused, 88 % recycled, 1 % landfill
       Concrete               0.50            0.091         5.8 % recycled, 94.2 % landfill
  Reinforced concrete         0.53            0.099         5.8 % recycled, 94.2 % landfill

EPD – Environmental Product Declarations, www.environdec.com
Environmental and economical assessment
                                  Manufacturing                                                               Pre-stressed concrete tower
                                                                                                                          Carbon     Energy
                                                Tubular steel tower                                          Material    intensity intensity
                                                        Carbon      Energy                                                [tonne]     [GJ]
                                          Material     intensity intensity                                  Concrete
                                                        [tonne]      [GJ]                                                  172.1      921
                                                                                                            segments
                                        Steel plates     232.6      3 426                                 Steel tendons     63.1      901
                                         Concrete        169.9       934                                  Reinforcement     22.9      326
                                       Reinforcement      36.9       526                                    Concrete        95.5      525
                                           Sum           439.4      4 866                                     Sum          353.6      2673
Carbon intensity [Tonnes CO 2]




                                 500                                                                    6000
                                                                                Energy intensity [GJ]
                                 400                                                                    5000

                                            232,6                                                       4000
                                 300
                                                                                                        3000         3426
                                                                   235,2
                                 200
                                                                                                        2000
                                                                                                                                          1822
                                 100        206,8
                                                                                                        1000
                                                                   118,4                                             1460
                                                                                                                                           851
                                  0                                                                       0
                                          Steel tower          Concrete tower                                     Steel tower         Concrete tower
Environmental and economical assessment
                                  Transportation                                                             Pre-stressed concrete tower
                                                                                                                         Carbon     Energy
                                               Tubular steel tower                                          Material    intensity intensity
                                                       Carbon      Energy                                                [tonne]      [GJ]
                                         Material     intensity intensity                                  Concrete
                                                       [tonne]      [GJ]                                                  13.49      195.5
                                                                                                           segments
                                       Steel plates      3.41       49.5                                 Steel tendons     0.14        2.1
                                        Concrete         1.28       18.5                                 Reinforcement     0.05        0.7
                                      Reinforcement      0.08        1.2                                   Concrete        0.72      10.4
                                          Sum            4.77       69.2                                     Sum           14.4      208.7
Carbon intensity [Tonnes CO 2]




                                 16                                                                    250
                                 14
                                                                               Energy intensity [GJ]
                                                                                                       200
                                 12
                                 10                                                                    150
                                 8                                13,63
                                                                                                       100                               197,5
                                 6
                                 4
                                           3,41                                                        50           49,5
                                 2
                                           1,36                    0,77                                             19,7                  11,2
                                 0                                                                      0
                                        Steel tower           Concrete tower                                     Steel tower         Concrete tower
Environmental and economical assessment
                                  Erection (fuel consumption of cranes, foundation excluded)

                                               Tubular steel tower                                            Pre-stressed concrete tower
                                                       Carbon      Energy                                                    Carbon    Energy
                                         Material     intensity intensity                                     Material      intensity intensity
                                                       [tonne]      [GJ]                                                     [tonne]     [GJ]
                                       Steel plates      8.46       94.8                                 Concrete segments 13.49        834.0
                                          Sum            8.46       94.8                                       Sum            13.49     834.0
Carbon intensity [Tonnes CO 2]




                                 80                                                                    900 000
                                 70
                                                                               Energy intensity [GJ]   800 000
                                 60                                                                    700 000
                                                                                                       600 000
                                 50
                                                                                                       500 000
                                 40                               74,42                                                                  831 041
                                                                                                       400 000
                                 30
                                                                                                       300 000
                                 20                                                                    200 000
                                 10                                                                    100 000
                                           8,46                                                                      94 808
                                 0                                                                           0
                                        Steel tower           Concrete tower                                       Steel tower        Concrete tower
Environmental and economical assessment
                                  Dismantling (recycling/incinerating plant situated 200 km away)

                                               Tubular steel tower                                            Pre-stressed concrete tower
                                                       Carbon      Energy                                                    Carbon    Energy
                                         Material     intensity intensity                                     Material      intensity intensity
                                                       [tonne]      [GJ]                                                     [tonne]     [GJ]
                                       Steel plates     28.70      416.0                                 Concrete segments 37.60        546.0
                                          Sum           28.70      416.0                                       Sum            37.60     546.0
Carbon intensity [Tonnes CO 2]




                                 40                                                                    600
                                 35
                                                                               Energy intensity [GJ]
                                                                                                       500
                                 30
                                                                                                       400
                                 25
                                 20                               37,60                                300
                                                                                                                                         546,0
                                 15       28,70                                                                     416,0
                                                                                                       200
                                 10
                                                                                                       100
                                 5
                                 0                                                                      0
                                        Steel tower           Concrete tower                                     Steel tower         Concrete tower
Environmental and economical assessment
                                  Total carbon and energy intensity
                                                 Tubular steel tower                                                   Pre-stressed concrete tower
                                                         Carbon         Energy                                                        Carbon    Energy
                                          Material      intensity      intensity                                      Material       intensity intensity
                                                         [tonne]         [GJ]                                                         [tonne]    [GJ]
                                       Manufacturing      439.4          4886                                      Manufacturing       353.6     2674
                                       Transportation       4.8           69                                       Transportation       14.4      209
                                          Erection          8.5           95                                          Erection          74.4      834
                                        Dismantling        28.7           416                                       Dismantling         37.6      546
                                           Sum            481.4          5466                                           Sum            480.0     4262
Carbon intensity [Tonnes CO 2]




                                 500                                                                        6000
                                                 28,7
                                                 8,5                      37,6      Energy intensity [GJ]                   416
                                 400                                      74,4                              5000            95

                                                                                                            4000                                   546
                                 300
                                                                                                                                                   834
                                                                                                            3000
                                                439,4                                                                       4886
                                 200                                      353,6
                                                                                                            2000
                                                                                                                                                  2674
                                 100                                                                        1000

                                  0              4,8                      14,4                                0              69                    209
                                              Steel tower          Concrete tower                                        Steel tower          Concrete tower
Environmental and economical assessment
Embodied CO2 in electricity produced

                       Total emissions   Electricity produced
                                                                   g CO2/kWh
                           [tonnes]             [GWh]
       Steel tower           480.1                70.1                6.85
      Concrete tower         481.4                70.1                6.87




Energy payback time
                       Embodied energy    Produced Energy
                                                                Months to recovery
                           [MWh]               [MWh]
       Steel tower        1 518.3               292                    5.2
      Concrete tower      1 183.9               292                    4.1
Innovations in foundations
More prefabrication
E.g. more prefabricated reinforcement:
- cages
- cell reinforcement
- roll out reinforcement
Alternative reinforcement solutions in foundations
Cell reinforcement – a new type of reinforcement in high strength steel
(1000 MPa). Rows of rings with specific ring diameters with great
ductile capability. Several rows of rings in two different directions form
a net reinforcement.
Vindforsk project on-going with dynamic tests of cell-reinforced beams
and slabs for possible application in foundations.
Alternative reinforcement solutions in foundations
                                 Cell reinforcement                                                                        Example from static tests:
                                                                                                                            Yield strength 500 MPa
                                                                                                                               Ductile behaviour
                	
                                                                                                                                     	
  
                                                       10∅8-­‐ N	
   s120	
  




                                                                     3∅12	
                                                                                                                            6	
   LYING	
   ROWS	
  

                                   325	
                               450	
                    325	
                                                                   325	
                                   450	
                                   325	
  
                                                        Reference	
   beam,	
   Ø12                                                                                               Cellreinforced	
   beam,	
   6	
   lying	
   rows	
   Docol	
   500
                                                                                                                    L1	
   	
   	
                                                                                                                                          L1	
   	
   	
  
                 450                                                                                                                                          450
                                                                                                                    L2	
   	
   	
                                                                                                                                          L2	
   	
   	
  
                 400                                                                                                                                          400
                                                                                                                    L3	
   	
   	
                                                                                                                                          L3	
   	
   	
  
                   350                                                                                                                                        350
                   300                                                                                                                                        300
Load	
   [kN]




                                                                                                                                       Load	
   [kN]


                   250                                                                                                                                        250
                   200                                                                                                                                        200
                       150                                                                                                                                    150
                       100                                                                                                                                    100
                       50                                                                                                                                      50
                        0                                                                                                                                       0
                             0     5         10   15      20         25          30   35   40   45        50   55             60                                    0    5        10       15        20        25         30        35        40        45        50   55             60
                                                                    Deformation	
   [mm]                                                                                                                      Deformation	
   [mm]
Conclusions
•  The competiveness of a wind power plant relies on 1. good wind
   conditions, 2. good and reliable turbines, 3. the height of the towers
   and how fast and cheap they can be built
•  Requirements for building higher towers: more cost effective, lower
   (no) maintenance costs, competitive foundations.
•  Solution is in innovations in the construction sector, that has a
   supportive role for the wind sector but may improve the image.
   Innovations such as new assembling techniques for steel towers,
   new reinforcement, design and construction of foundations, blade
   materials and design …
Conclusions
•  Environmental and economical assessment are important tools for
   future investments (given example shows almost no difference
   between steel or concrete structures; about 7 g CO2/kwh)

•  Possible solutions and competence are within Swedish Universities
   of the Built Environment (LTU, Chalmers, KTH, LTH) where further
   improvements are planned.

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Sustainable solutions for faster construction of the higher tower and foundation

  • 1. Sustainable solutions for faster construction of the higher tower and foundation Tech. Dr. Martin Nilsson Luleå University of Technology Division of Structural and Construction Engineering – Structural Engineering Martin.C.Nilsson@ltu.se Prof., Tech. Dr. Milan Veljkovic Luleå University of Technology Division of Engineering and Construction Structural – Steel Structures Milan.Veljkovic@ltu.se
  • 2. Agenda •  Introduction, demands on improved competitiveness. •  The complete assessment: design, environmental and economical life cycle assessment. •  Innovations in foundations. •  Conclusions.
  • 3. Future requirements By year 2020, 30 TWh of the electricity consumption in Sweden should be produced by wind power. (Target by Swedish Wind Energy). Wind power plants will be constructed at remote locations, in short time and under harsh climate conditions. The plants must have good locations, good turbines and be built both quickly and competitively Wind power plants must be designed with sustainable solutions, both environmentally and economically. Turbines have to be built higher than 100 m to gain stable and more constant wind.
  • 4. New demands for competitiveness on wind energy sector The future requirements impose new demands on costs and effectiveness of: –  turbine design, –  wings, including de-icing where necessary, –  bearing structural components – towers and foundations, production and assembling for higher towers
  • 5. Economics of Wind Power UK experience On‑shore Offshore Element Cost as % of total Cost as % of total • Turbine • 33% • 21% • Blades • 22% • 15% • Tower • 20% • 13% • Foundation • 9% • 21% • Grid connection • 6% • 21% • Design & Management • 10% • 9% • Total cost per MW • €1.5 - 2 million • €2.5 – 3.5 million
  • 6. Existing and alternative tubular steel tower solutions
  • 7. Existing concrete tower solutions Prefabricated elements In-situ cast with slip form 1 2 3
  • 8. Environmental and economical assessment Economical and environmental life cycle assessment of an on-shore wind power structure focusing on embodied equivalent CO2 emissions and energy consumed in manufacturing, transportation, erection and dismantling. Example from Master Thesis by Josep Pigem Rodeja, LTU: The mass of CO2 and energy used per produced kWh at consumers place for a 100 m high tubular steel tower and a pre-stressed concrete tower with foundation
  • 9. Environmental and economical assessment Approximate structural design, equivalent loading P 1.  Ultimate Limit State (ULS) - Enough strength of materials. - Instability phenomena. P 2.  Fatigue Limit State (FLS) - Steel: structural details. - Concrete: Separately by material O 3.  Dynamic Stability - Vibration behaviour. - Avoid resonance problems.
  • 10. Environmental and economical assessment Ømin = 3m Geometrical approach 100 m Cross-section Conical tower
  • 11. Environmental and economical assessment Steel tower Concrete tower Østrand = 15.7 mm ns = 12 ntendon = 56
  • 12. Environmental and economical assessment Material data Carbon intensity Energy intensity Material Recovery [kg CO2/kg] [MJ/kg] Steel plates 11.78 0.800 11 % reused, 88 % recycled, 1 % landfill Reinforcement 12.42 0.870 11 % reused, 88 % recycled, 1 % landfill Concrete 0.50 0.091 5.8 % recycled, 94.2 % landfill Reinforced concrete 0.53 0.099 5.8 % recycled, 94.2 % landfill EPD – Environmental Product Declarations, www.environdec.com
  • 13. Environmental and economical assessment Manufacturing Pre-stressed concrete tower Carbon Energy Tubular steel tower Material intensity intensity Carbon Energy [tonne] [GJ] Material intensity intensity Concrete [tonne] [GJ] 172.1 921 segments Steel plates 232.6 3 426 Steel tendons 63.1 901 Concrete 169.9 934 Reinforcement 22.9 326 Reinforcement 36.9 526 Concrete 95.5 525 Sum 439.4 4 866 Sum 353.6 2673 Carbon intensity [Tonnes CO 2] 500 6000 Energy intensity [GJ] 400 5000 232,6 4000 300 3000 3426 235,2 200 2000 1822 100 206,8 1000 118,4 1460 851 0 0 Steel tower Concrete tower Steel tower Concrete tower
  • 14. Environmental and economical assessment Transportation Pre-stressed concrete tower Carbon Energy Tubular steel tower Material intensity intensity Carbon Energy [tonne] [GJ] Material intensity intensity Concrete [tonne] [GJ] 13.49 195.5 segments Steel plates 3.41 49.5 Steel tendons 0.14 2.1 Concrete 1.28 18.5 Reinforcement 0.05 0.7 Reinforcement 0.08 1.2 Concrete 0.72 10.4 Sum 4.77 69.2 Sum 14.4 208.7 Carbon intensity [Tonnes CO 2] 16 250 14 Energy intensity [GJ] 200 12 10 150 8 13,63 100 197,5 6 4 3,41 50 49,5 2 1,36 0,77 19,7 11,2 0 0 Steel tower Concrete tower Steel tower Concrete tower
  • 15. Environmental and economical assessment Erection (fuel consumption of cranes, foundation excluded) Tubular steel tower Pre-stressed concrete tower Carbon Energy Carbon Energy Material intensity intensity Material intensity intensity [tonne] [GJ] [tonne] [GJ] Steel plates 8.46 94.8 Concrete segments 13.49 834.0 Sum 8.46 94.8 Sum 13.49 834.0 Carbon intensity [Tonnes CO 2] 80 900 000 70 Energy intensity [GJ] 800 000 60 700 000 600 000 50 500 000 40 74,42 831 041 400 000 30 300 000 20 200 000 10 100 000 8,46 94 808 0 0 Steel tower Concrete tower Steel tower Concrete tower
  • 16. Environmental and economical assessment Dismantling (recycling/incinerating plant situated 200 km away) Tubular steel tower Pre-stressed concrete tower Carbon Energy Carbon Energy Material intensity intensity Material intensity intensity [tonne] [GJ] [tonne] [GJ] Steel plates 28.70 416.0 Concrete segments 37.60 546.0 Sum 28.70 416.0 Sum 37.60 546.0 Carbon intensity [Tonnes CO 2] 40 600 35 Energy intensity [GJ] 500 30 400 25 20 37,60 300 546,0 15 28,70 416,0 200 10 100 5 0 0 Steel tower Concrete tower Steel tower Concrete tower
  • 17. Environmental and economical assessment Total carbon and energy intensity Tubular steel tower Pre-stressed concrete tower Carbon Energy Carbon Energy Material intensity intensity Material intensity intensity [tonne] [GJ] [tonne] [GJ] Manufacturing 439.4 4886 Manufacturing 353.6 2674 Transportation 4.8 69 Transportation 14.4 209 Erection 8.5 95 Erection 74.4 834 Dismantling 28.7 416 Dismantling 37.6 546 Sum 481.4 5466 Sum 480.0 4262 Carbon intensity [Tonnes CO 2] 500 6000 28,7 8,5 37,6 Energy intensity [GJ] 416 400 74,4 5000 95 4000 546 300 834 3000 439,4 4886 200 353,6 2000 2674 100 1000 0 4,8 14,4 0 69 209 Steel tower Concrete tower Steel tower Concrete tower
  • 18. Environmental and economical assessment Embodied CO2 in electricity produced Total emissions Electricity produced g CO2/kWh [tonnes] [GWh] Steel tower 480.1 70.1 6.85 Concrete tower 481.4 70.1 6.87 Energy payback time Embodied energy Produced Energy Months to recovery [MWh] [MWh] Steel tower 1 518.3 292 5.2 Concrete tower 1 183.9 292 4.1
  • 19. Innovations in foundations More prefabrication E.g. more prefabricated reinforcement: - cages - cell reinforcement - roll out reinforcement
  • 20. Alternative reinforcement solutions in foundations Cell reinforcement – a new type of reinforcement in high strength steel (1000 MPa). Rows of rings with specific ring diameters with great ductile capability. Several rows of rings in two different directions form a net reinforcement. Vindforsk project on-going with dynamic tests of cell-reinforced beams and slabs for possible application in foundations.
  • 21. Alternative reinforcement solutions in foundations Cell reinforcement Example from static tests: Yield strength 500 MPa Ductile behaviour     10∅8-­‐ N   s120   3∅12   6   LYING   ROWS   325   450   325   325   450   325   Reference   beam,   Ø12 Cellreinforced   beam,   6   lying   rows   Docol   500 L1       L1       450 450 L2       L2       400 400 L3       L3       350 350 300 300 Load   [kN] Load   [kN] 250 250 200 200 150 150 100 100 50 50 0 0 0 5 10 15 20 25 30 35 40 45 50 55 60 0 5 10 15 20 25 30 35 40 45 50 55 60 Deformation   [mm] Deformation   [mm]
  • 22. Conclusions •  The competiveness of a wind power plant relies on 1. good wind conditions, 2. good and reliable turbines, 3. the height of the towers and how fast and cheap they can be built •  Requirements for building higher towers: more cost effective, lower (no) maintenance costs, competitive foundations. •  Solution is in innovations in the construction sector, that has a supportive role for the wind sector but may improve the image. Innovations such as new assembling techniques for steel towers, new reinforcement, design and construction of foundations, blade materials and design …
  • 23. Conclusions •  Environmental and economical assessment are important tools for future investments (given example shows almost no difference between steel or concrete structures; about 7 g CO2/kwh) •  Possible solutions and competence are within Swedish Universities of the Built Environment (LTU, Chalmers, KTH, LTH) where further improvements are planned.