The document discusses the growing global market for wind energy and precast concrete wind towers and offshore foundations. It summarizes Consolis Hormifuste's products and experience, including hybrid and full concrete towers up to 150 meters tall, and gravity-based offshore foundations up to 25 meters deep designed for serial production using precast concrete pieces. The company aims to reduce costs through standardized, land-based precasting and efficient sea transport methods.

1. PRECAST
CONCRETE
WIND TOWERS
AND
OFFSHORE
FOUNDATIONS:
A HUGE MARKET
COMING AHEAD
Jaime de Rábago,
Managing Director, Consolis Hormifuste S.A.
Madrid, 13/05/2011
EOI: Claves para emprender en renovables 1

2. Content
 About Consolis Group
 About Consolis Hormifuste
 Understanding wind
 Consolis Hormifuste products and services
 Consolis Hormifuste onshore
 Consolis Hormifuste offshore
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3. Consolis history
 100+ years of history
 Consolis Oy in Northern Europe
 Bonna Sabla in France & North Africa
 Today, European leader
in pre-cast concrete industry
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4. Activity area (23 countries):
• Europe
• North Africa
• Asia
Personnel: ~ 10000
Turnover: + 1500 M€
Factories: ~ 130
Headquarter: Brussels
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5. Solutions for
•Residential & non-residential
buildings
•Railways
•Civil works (pipes,
environment etc.)
•Unlimited…
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6. Continuous innovation
 Consolis Technology (Finland-France) at
the cutting edge
 Developing pre-cast concrete concepts,
products, manufacturing processes and raw
materials to improve productivity and quality
 Technology Roadmap
boosting internal co-operation
 Consolis Innovation Training (CIT)
• intensify & better manage innovation
• improve the transfer of best practices
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7. People & practices
 Skills development – a top priority
 Training – a major investment
Consolis Academy
 Transfer of best practices (TOB)
sharing experience among Consolis companies
 International functional networks
sharing knowledge and building synergies
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8. Respect for the environment
New ideas for sustainability over the entire product life cycle
 better use of materials
 production with reduced environmental burden
 design for re-use/dismantling/recycling
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9. Consolis Hormifuste S.A.
The wind tower centre of Consolis, located in Madrid
 Since 2008 a member of Consolis Group and since 2005 in the
renewable energy business.
 Coordination of product development and design
 Certification of solutions
 Customer relationships
 Coordination of marketing and sales
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10. Understanding wind
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11. Wind energy basics
How we obtain the energy from wind?
A: Area of the rotor
FORMULA: and D: Rotor diameter
V: Wind speed
P: Power output
So, energy is:
 in square proportion to rotor diameter
 in cubic proportion to wind speed
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12. 190
180
170
Wind energy basics 160
150
 hub height
140
 rotor diameter 130
120
... both parameters of 110
paramount 100
IMPORTANCE 90
80
to increase
70
energy production
60
50
40
30
20
10
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13. The world wind industry
Cumulative Global Wind Power Development
Today: nearly 200.000 Mw Actual 1990-2010 Forecast 2011-2015 Prediction 2016-2020
1,100,000
installed in a global scale
1,000,000
-Year 2015: 500.000 Mw 900,000
800,000
-Year 2020: ….nearly 700,000
1.100.000 Mw!! 600,000
MW
500,000
-Wind industry: growth, 400,000
growth, growth 300,000
200,000
100,000
One tower (windmill) = 2 - 5 MW
0
On-shore / off-shore 1990 2010 2015 2020
Source: BTM Consult - A Part of Navigant Consulting - Prediction Forecast Existing capacity
March 2011
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14. From MW to concrete towers
> 2,5 MW  1,5-2,5 MW  0,75-1,49 MW  < 0,75 MW
100%
90%
80%
The evolution of MW 70%
per WTG in different 60%
segments is as follows 50%
(average composed 40%
nominal power) 30%
20%
10%
2003 2004 2005 2006 2007 2008 2009 2010 2011 2012
Source: real data up to 2009, then, own estimations
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15. A market of bigger and higher machines…
Year 1970 1980 1983 1985 1987 1990 1995 1998 2000 2003
Height (m) 10 15 20 25 30 50 60 70 85 110
Rotor Ø (m) 5 11 12,5 20 23 48 58 61 77 116
Power (kW) 5 20 30 100 100 600 1100 1200 1500 5000
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16. Why concrete towers for the wind industry?
… there are technical reasons…
 Less maintenance requirements
 More flexibility of construction and design
 Better dynamic response (less vibrations and fatigue)
 Better transportation possibilities
 Precast plants can be easily adapted for manufacturing of
concrete towers
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17. Why concrete towers for the wind industry?
… and economic reasons Approx. cost comparison
between concrete and steel
 Variation of steel prices wind towers
 With greater and higher wind
turbines (> 100 meters), the
concrete solutions for towers is
cheaper
 The tower can account for up to
20-25% of the total wind farm cost
and this percentage increases Concrete
with greater turbines Steel
60 70 80 90 100 110 120 130 140 150
Tower height (metres)
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18. Consolis product range for wind farms
 Onshore
• Hybrid precast concrete-steel towers
• Full precast concrete tower
 Offshore
• Precast concrete gravity based foundations
Consolis does
 Design
 Production
 Transportation to the building site
 Assembly and other site works
 Post tensioning
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19. Hybrid precast Steel part
concrete-steel tower
- max height 150 m
Post tensioning
cables
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20. Full concrete tower
- max height 105 m
Intermediate slab
Post tensioning
cables
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21. Consolis
Hormifuste
solution
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22. Consolis Hormifuste solution
1. Technical Introduction
1.1 Basic Vocabulary
1.2 Classical Structures vs. Wind Towers
2. General Calculation Scheme
3. Calculation Process
1 Wind Turbine Manufacturer Data
2 Geometry and Post-tension
3 Pieces reinforcement
4 Joints
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23. 1. Technical introduction
1.1. Basic Vocabulary
• Geometry: tower shape
• Joints: connections between pieces
• Own frequency of structure: dynamic behaviour parameter to be
controlled in order to avoid interaction with the turbine→ Resonance
• ULS: Ultimate Limit State of strength, stability and fatigue. Loads that
should cause the collapse of the structure
• SLS: Serviceavility Limit State. We differentiate between extreme loads
(50 years return period) and frequent loads (one year return period)
• Fatigue: Time repeated loads → load cycles and damage accumulation
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24. 1. Technical introduction
1.2 Classical Structures vs. Wind Towers
In an classical structure ,design is
conditioned by SLS and ULS. Once we
have the structural design the fatigue is
checked.
In concrete wind towers initial design is
conditioned by SLS and fatigue. After this,
ULS are checked. Fatigue is determinant in
calculation, as the cycles are huge (108)
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25. 2. General Calculation Scheme
WT Manufacturer Data 1
SLS Max. Fatigue Load
Geometry and
2 Geometry
Post tension
Modification
Own Fatigue
Frequency Loads
Accumulated damage
3
Vertical
Pieces
ULS, shear and torsion General
reinforcement
Horizontal
Joints 4
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26. 3. Calculation process
1 Wind Turbine Manufacturer Data
Main data to be provided by Wind Turbine Manufacturer:
Loads and Markov Matrix of bending moments at different heights of the
tower
Clearance: Minimum distance to maintain between blade tip and the
tower.
Frequency: Tower Frequency used in loads calculation.
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27. 3. Calculation process
2 Geometry and Post-tension
Once the geometry and
Ring Number Weight of
post tension is of each
elements element
confirmed, the tower is per ring
divided in precast units 1 6 25,4
(rings and elements per 2 6 26,9
ring) 3 6 26,4
4 5 28,2
5 5 24,7
6 4 24,5
7 4 22,8
8 3 28,3
9 3 26,1
Detailed geometry
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28. 3. Calculation process
3 Pieces reinforcement
Horizontal reinforcement is
necessary to support shear and
torsion forces caused by temperature
gradient between inner and outer
part of the tower
Vertical reinforcement is only
necessary for handling of pieces
Reinforcement of precast elements
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29. 3. Calculation process
4 Joints
Proper
reinforcement
and grouting of
vertical joints
during assembly
will assure the
monolithic
behaviour of rings
Detail of the vertical joint Detail of the horizontal joint 29

30. Our first project:
100 metres hybrid towers in Finland
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31. 31
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33. 33

34. 34

35. 35

36. 36

37. 37

38. 38

39. 39

40. 40

41. Consolis Hormifuste solutions for offshore
Since 2007, Consolis-Hormifuste has carried out several works concerning offshore
wind turbines. These works range from basic studies to the designs of a concrete
foundation structure, designed to perform in different conditions.
The following studies have been developed until now:
•Research proposal for offshore concrete foundations for wind turbines
• Structural and stability calculations for an offshore windturbine foundation
• Foundations for offshore wind turbines: state of the art
• Founfations for offshore wind turbines: Analysis of structural solutions
• Foundations for offshore wind turbines: Analysis of a conical caisson in locations with
25 m of depth
• Foundations for offshore wind turbines: Analysis of precast pieces for a foundation
structure in locations with 25 m of depth
In the following slides, a summary of these works is made.
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42. Consolis Hormifuste solutions for offshore
RESEARCH PROPOSALS
In this study, a brief and preliminar state of the art was made, and some research
lines were proposed:
• Predesign abacus
• Construction methodologies
• Economic evaluations
• Environment evaluations
Some of these lines would be developed then in the following works
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43. Consolis Hormifuste solutions for offshore
STRUCTURAL AND STABILITY CALCULATIONS FOR
AN OFFSHORE WIND TURBINE FOUNDATION
Here, a design of a foundation made of a reinforced concrete caisson was developped.
The caisson was designed for depths from 10 to 30 meters, and with the ability to be
transported afloat .
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44. Consolis Hormifuste solutions for offshore
ANALYSIS OF STRUCTURAL SOLUTIONS
Two structural solutions were studied here, both of them valids to perform at depths of
50 m.
Solution #1: a
conical caisson
supporting a
cylindrical structure
Solution #2: three
piles supporting a
cylindrical structure
Both solutions were designed to be transported afloat.
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45. Consolis Hormifuste solutions for offshore
CONICAL CAISSON IN LOCATIONS FOR UP TO 25m SEA DEPTH
(2009-2010)
It was inferred from the former study that the conical solution had lower costs than the
three pile solution.
A foundation structure for 25 m depth, made of a conical caisson which was able to
be transported afloat was designed.
The following calculations were carried
out for this solution:
•Buoyancy of the foundation structure
•Geotechnical stability
• Structural calculations
• Estimated costs
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46. Consolis Hormifuste solutions for offshore
ANALYSIS OF PRECAST PIECES FOR A FOUNDATION STRUCTURE
IN LOCATIONS FOR UP TO 25m SEA DEPTH
Finally, a design of the conical caisson making
use of precast pieces was developed.
-The foundation structure was made to perform
up to 25 m depth.
-It was designed to be built on the coastline
and then transported afloat.
-The reinforcement was made with
post-tensioning tendons, due to the high tensions.
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47. Offshore foundation for
up to 25m sea depth
Bottom diameter: 22 m
Height of conical part 18,5 m
Total height 25 m
The foundation has vertical
and horizontal post tension.
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48. Offshore costs... the big battle in the
coming years
 Cost comparison? Not yet possible in real terms:
 A lot of different sites, depths and tipologies
 Good reference: Vattenfall Kriegers Flak conceptual
foundation study (5Mw, 35 metres, 40 foundations, 5 types:
between 2,4 Meur to 3,8Meur)
 Our solution has a clear aim: reducing cost in the production
phase. Transportation and installation should not vary a lot
from other solutions.
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49. Precast advantages for offshore...
 Serial production as big amount of pieces to be
precasted
 High quality guaranteed at factory
 Pieces easy to transport (no more than 20 tons each)
to harbour or to coastline
 Small area needed in harbour and or coastline
 Possibility of keep independent production from
installation: not dependent on weather conditions…
 Sea tranportation not too difficult…
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50. We want to avoid this...!
50

51. .. and even this...!
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52. Let’s harness wind together!!
CONSOLIS HORMIFUSTE S.A.
C/ José Silva, 3 4ºD
28043 Madrid (SPAIN)
info@hormifuste.es
www.consolis.com
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