aspasa eastern cape regional committee meeting_20151008-without scc video

Concrete for Wind Turbine Towers

ASPASA-SARMA Regional Committee Meeting October 2015

Santie Gouws

Concrete Tower Manager

santie.gouws@acciona.com

AGENDA

Acciona Windpower Overview

South African Wind Energy Industry

Acciona Windpower’s Concrete Towers

- Industrialized precast manufacture

- Overview of tower construction and manufacture of concrete segments

Why Concrete Towers?

- High strength SCC to EN 206

1

South African Wind Energy Industry

Integrated Resource Plan 2010-2030

South Africa

SOUTH AFRICAN WIND ENERGY INDUSTRY

SANTIE GOUWS

DoE presented IRP 2010 to 2030 in 2010 to diversify South African electricity generation mix:

Source Initial capacity 2010 Addition 2010-2030 Final Capacity 2030

Coal 24.6 GW - 74.8% 16.4 GW 41.1 GW - 46%

Natural Gas 2.4 GW - 7.2% 4.9 GW 7.3 GW - 8.2%

Nuclear 1.8 GW - 5.4% 9.6 GW 11.4 GW - 12.7%

Hydro 2.1 GW - 6.3% 3.3 GW 5.4 GW - 6.0%

Wind 0 GW - 0% 9.2 GW 9.2 GW - 10.3%

Solar PV 0 GW - 0% 8.4 GW 8.4 GW - 9.4%

Solar CSP 0 GW - 0% 1.2 GW 1.2 GW - 1.3%

TOTAL 33 GW 56.5 GW 89.5 GW

RE Independent Power Producer Procurement Programme

South Africa

SOUTH AFRICAN WIND ENERGY INDUSTRY

SANTIE GOUWS

DoE’s REIPPP Programme engages private companies to generate renewable energy through several bid windows:

WIND Awarded Nr of Projects Capacity COD

Round 1 Dec 2011 7 626 MW (wind only) 2nd half 2013

Round 2 May 2012 7 571 MW (wind only) 1st half 2015

Round 3 Oct 2013 7 787 MW (wind only) 1st half 2016

Round 4a April 2015 5 676 MW (wind only)

Round 4b June 2015 7 687 MW (wind only)

Expedited bid 1st Qtr 2016 ? 1800 MW (all renewables)

Round 5 onwards 2016 - 2018 ? 6300 MW (all renewables)

SOUTH AFRICAN WIND ENERGY INDUSTRY

SANTIE GOUWS

Distribution of Bid 1 to 4 Projects

Importance of Local Economic Development in REIPPP Programme

South Africa

SOUTH AFRICAN WIND ENERGY INDUSTRY

SANTIE GOUWS

Project Qualification is based on:

Environment, Land, Commercial

Economic Development Finance Technical

Project Evaluation is based on:

Price________________________________70%

Economic Development_________________30% - threshold up to round 4 ~ 40%

- set to increase from round 5 onwards

Local Spend

Job Creation

ED Scorecard

Cost of Electricity

2

Why Concrete Towers?

South Africa

WHY CONCRETE TOWERS? SANTIE GOUWS

Wind turbine development – turbine size and hub height

South Africa

WHY CONCRETE TOWERS? SANTIE GOUWS

Wind energy project value

Source: DTI based on Bid

Window 3 data for South

Africa

Concrete Towers > 95% local content

Concrete Towers are cost effective > 90m

Local Economic Development

Price

Further advantages of concrete towers

South Africa

WHY CONCRETE TOWERS ?

SANTIE GOUWS

Tower diameter and segment size not limited based on transport limitations

Further advantages of concrete towers

SANTIE GOUWS

Possibility to manufacture in remote locations, reduce transport cost and impact on roads and employ local labour from wind farm locale

WHY CONCRETE TOWERS?

3

ACCIONA Windpower Overview

OVERVIEW OF ACCIONA WINDPOWER

SANTIE GOUWS

Countries with AWP turbines installed

Widespread international footprint to capture future growth in the most attractive markets

A high quality wind turbine manufacturer with a global presence

Strong proprietary technology portfolio:

Fully in-house developed and certified turbine design

In-house blade design

Patented and certified concrete tower design

OVERVIEW OF ACCIONA WINDPOWER

Acciona Windpower presence

Designs and produces reliable and one of the lowest cost of energy wind turbines for Class I, II and III winds:

1.5 MW

3.0 MW

6.0 MW under development

SANTIE GOUWS

SANTIE GOUWS

Manufacturing

Vertical integration strategically limited to the key components (i.e. blades, towers and software control)

SUPPLIERS

Blades Towers Software control Yaw Gearboxes Generator

Local Manufacturers

OWN SUPPLY (Concrete towers)

REASON

LM controls the market.

Superior in-house design

Local markets with low value added

from technologies, except for concrete

Critical to optimize performance of turbines

Mature market Mature market Mature market

OVERVIEW OF ACCIONA WINDPOWER

Dimensions of AWP 3.0 MW Wind Turbine Generators

OVERVIEW OF ACCIONA WINDPOWER

Blades:

Length: 48m – 61.5m

Weight: 10t – 12t

SANTIE GOUWS

Nacelle & Hub:

Length: 17.6m

Weight: 140t

Tower:

Length: 87.5 to 95.5m (Steel); 100 to 120m (Concrete)

Weight: 290t (95.5m Steel); 1180t (120m Concrete)

South Africa

OVERVIEW OF ACCIONA WINDPOWER

SANTIE GOUWS

4

ACCIONA Windpower Concrete Towers

ACCIONA WINDPOWER CONCRETE TOWERS

SANTIE GOUWS

Overview of Concrete Tower Construction Process

Segment Manufacture

• Industrialized Precast

• High Strength SCC

• 20m long segments

• 60tonnes/segment

ACCIONA WINDPOWER CONCRETE TOWERS

SANTIE GOUWS

Overview of Concrete Tower Construction Process

Transport

Pre-Assembly

• 20m cylinders

• Vertical Joints

• Small cranes only

• 2 t/w

• 1-2 weeks ahead of erection

ACCIONA WINDPOWER CONCRETE TOWERS

SANTIE GOUWS

Overview of Concrete Tower Construction Process

Pre-Assembly Phase

• 17/22 segments/tower for 100/120m tower

• Level 0 – 5 segments (120m tower)

• Level 1 – 4 segments (100m tower)

• Level 2 – 4 segments

• Level 3 – 4 segments

• Level 4 – 3 segments

• Level 5 – 2 segments

ACCIONA WINDPOWER CONCRETE TOWERS

SANTIE GOUWS

Overview of Concrete Tower Construction Process

Final Assembly Phase

• Crawler crane 1-d operation

• 2t/w or more

• Independent of horizontal joint execution

• Independent external post-tensioning of tower

ACCIONA WINDPOWER CONCRETE TOWERS

SANTIE GOUWS

Overview of Concrete Tower Construction Process

Final Assembly Phase

• Same crane as needed for nacelle

ACCIONA WINDPOWER CONCRETE TOWERS

SANTIE GOUWS

Overview of Concrete Tower Construction Process

DESIGNED FOR (global) RE-PRODUCTION

ACCIONA WINDPOWER CONCRETE TOWERS

SANTIE GOUWS

Overview of Concrete Segment Manufacturing Process

Casting Schedule

• 1 mould/tower level

• 5/6 for 100/120m t

• 1 to 2 casts/mould/d

• 6d/w

ACCIONA WINDPOWER CONCRETE TOWERS

SANTIE GOUWS

Overview of Concrete Segment Manufacturing Process

Batching/casting

• Wet-batch only

• Ready-mix and/or pump

ACCIONA WINDPOWER CONCRETE TOWERS

SANTIE GOUWS

Overview of Concrete Segment Manufacturing Process

Concrete Specification

• Self compacting concrete

• Flow of 750 mm

• Superplasticizers to reduce w/b ratio to < 0.35

• Highly sensitive to moisture, gradings and temperature

• Requires stringent control of raw materials and batching process

ACCIONA WINDPOWER CONCRETE TOWERS

SANTIE GOUWS

Overview of Concrete Segment Manufacturing Process

Concrete Specification

• EN 206/EN 1992

• fcu = 75 MPa cube

• Demould at 25 MPa

ACCIONA WINDPOWER CONCRETE TOWERS

SANTIE GOUWS

Overview of Concrete Segment Manufacturing Process

Finishing and Repair

• Segments functional requirements for tower construction and operation

• Vertical Joints

• Starter bars and Horizontal joints

• Internal tower fixtures

• Surface finish

• Managed through quality system

ACCIONA WINDPOWER CONCRETE TOWERS

SANTIE GOUWS

Overview of Concrete Segment Manufacturing Process Quality Management

• Linked to tower certification

• Stringent measurement and recording of all aspects

ACCIONA WINDPOWER CONCRETE TOWERS

SANTIE GOUWS

Overview of Concrete Segment Manufacturing Process Quality Management

• Paper-trail controlling all aspects and ensuring traceability

• From raw materials receipt to batch records to placing of steel and concrete, test results and numbering of segments through to position in tower

ACCIONA WINDPOWER CONCRETE TOWERS

SANTIE GOUWS

Industrialized precast construction Industrialized precast

• Fast-track construction

• Linked to wind farm construction schedule

• Planning and logistics management of all processes

• Planning of factory lay-out and schedule

ACCIONA WINDPOWER CONCRETE TOWERS

SANTIE GOUWS

Industrialized precast construction Industrialized precast

• Fast-track construction

• Linked to wind farm construction schedule

• Planning and logistics management of all processes

• Planning of factory lay-out and schedule

ACCIONA WINDPOWER CONCRETE TOWERS

SANTIE GOUWS

Industrialized precast construction Industrialized precast

• Fast-track construction

• Linked to wind farm construction schedule

• Planning and logistics management of all processes

• Planning of factory lay-out and schedule

ACCIONA WINDPOWER CONCRETE TOWERS

SANTIE GOUWS

Industrialized precast construction Industrialized precast

• Fast-track construction

• Linked to wind farm construction schedule

• Planning and logistics management of all processes

• Planning of factory lay-out and schedule

ACCIONA WINDPOWER CONCRETE TOWERS

SANTIE GOUWS

Industrialized precast construction

Thank you