Two simply but effective foundation solutions are the rock anchor, designed for a wind park in Mexico and the high plinth solution for a wind farm in Chile. They are highly cost efficient, feasible and have proven to be very reliable in many projects.
Bilbao (ESP) – Special requests often demand tailormade solutions. But tailormade needs an high specialization and a lot of knowhow from the engineers in the specific field. In foundation design for wind turbine generator (WTG), this specific knowledge is not that common, except for CTE Wind International. Their senior engineers are often asked to find new design solutions. For this purpose, they resort to tried and tested instead of reinventing the wheel. Two simply but effective solutions are the rock anchor and the high plinth solution. They aren’t NEW solutions but are highly cost efficient, feasible and their reliability has been proved in many projects. This article features two project cases, among many others, where CTE Wind International designed a rock anchor for a wind park in Mexico and a high plinth foundation for a wind farm in Chile.
Cost savings thanks to rock anchor
In Mexico CTE Wind Ibérica was selected as WTG foundation designer by a Spanish EPC company. The project has more than 20 WTGs with concrete towers. The project analysis conducted by the Spanish expert in foundation design has led to the recommendation to deploy two different solutions in order to optimize the costs of project. In fact, the soil conditions showed that over a third of the wind turbines were planned on rocky ground. Rather than equipping all wind turbine with standard slab foundations, CTE Wind’s engineering team decided together with the customer to implement rock anchors. This solution uses the rock masses as a WTG foundation. In that way the construction company is able take advantage of the earth crust instead of building a slab foundation. The costs for the reinforced concrete and the construction work can be saved. But this solution is specially challenging as the engineers have to adapt the foundation, with an interface, between the concrete towers and the rock anchors. Not to forget the special design work of these anchors that needs to be done. Finally, the client was impressed and satisfied about the result. But more important: the project costs were below the initial budget.
High plinth for extra height
In another case, CTE Wind was approached by a global construction company and explained the challenge for its project in Chile, with over 35 WTGs. The customer needed an hub height of 4 meters more to increase the energy production and ensure the yield and so its income. They weren’t totally satisfied with a complex solution by one of CTE Wind’s competitors. That is why the construction company asked CTE Wind to find a simple, reliable, feasible and cost-effective solution. That is how the high plinth foundation was chosen: a solution already tested and implemented in multiple projects in Europe. The idea of this foundation is to reach higher hub height with a high pedestal. The tower stands 3 to 6 meters above the «ground level», keeping the gravity foundation independent from the tower system. Ideally the solution provides a longer anchor cage. CTE Wind’s engineering team designed the anchor cage for this project and determined the bolt length and steel quality. If needed CTE Wind can also prepare the detailed anchor cage drawing. After comparing the results of CTE Wind’s predesigns to the competitor’s solutions, the customer decided to go ahead with CTE Wind’s high plinth foundation. No difficulties in regards the construction have been reported. On the contrary, the Spanish expert of WTG foundation design was congratulated.
France: Increasing Hub-Heights and Project Requirements×
Increasing Hub-Heights and Project Requirements
WTG Foundation Design in France
With the Soft-Spot® CTE Wind Civil Engineering captures the spirit of the times. The success is not only due to the new design solution. It is more a result of the developers increasing projects requirements and the size of the turbines. CTE Wind masters both easily.
La Richardais (FRA) – CTE Wind International, expert in foundation design for wind turbine generators, has his finger on the pulse of time with the Soft-spot® solution. Trademarked and patented in France (patent pending worldwide), 750 wind turbines use the resource saving solution worldwide. Over the half of the 50 realized projects related to the Soft-Spot® are located in France.
The success of the civil engineering company CTE Wind is not only due to the Soft-Spot®. It mainly relies on the fact that CTE Wind can master the increasing requirements of the wind energy developers. Wind farms have to be designed in a way that saves resources and allows fast set-up times; two important factors which determine the construction costs of WTG foundations.
A further driver and important point why developers choose CTE Wind is the increasing size of the turbines. Four to five years ago, the hub height of wind turbines ranged between 80 and 90 meters. Today the average hub heights of CTE Winds projects are between 110 and 120 meters. Some of the final designs even had a hub height far above average. The highest hub height ever calculated by CTE Wind stands in Salzgitter Germany with 166 meters.
Adapting the design to soil conditions
CTE Wind adapts its foundations designs to the local soil conditions and in accordance with applicable national and international standards. To avoid extremely large foundations CTE Wind’s engineering team has found with the Soft-Spot® a good and reliable solution to meet the mentioned resource-saving requirements. The construction is very easy and it allows savings in concrete volume up to 15% and a total weight reduction of reinforcement bars of 7 to 9%. Thanks to the reduction of the foundation diameter the earthwork to be handled is also reduced. This leads to less surface use for the foundation.
CTE Wind swoops on WTG foundation design projects in Andean region .
Bilbao (ESP) /La Richardais (FRA) – CTE Wind Ibérica, the Spanish Branch of CTE Wind International, has secured several contracts to deliver foundation design and geotechnical services for multiple wind farms in Colombia, Ecuador and Peru. In Ecuador, the expert in foundation design for wind turbine generators (WTG), has already finished its project for a wind farm with nearly 25 turbines. In Colombia CTE Wind is working on foundation design for a couple of wind parks and in Peru a new final design project will start in the very next days.
Enrique MARTINEZ, Commercial Manager of CTE Wind Ibérica said: «We are thrilled to work in those projects in the Andean region, which due to tectonic movements is a complex and challenging environment. This shows the trust that our customers have in our capabilities.»
Earthquakes and volcanic eruptions
Since earlier this year the structural engineering company has also been working on various projects in Chile, with globally 100 WTGs counting. Thanks to this achievement CTE Wind Ibérica worked in almost all Andean states. And this, in a region where tectonic forces can result in minor to major earthquakes and volcanic eruptions! But thanks to CTE Wind’s internal Geotech engineers these normal geological activities are no problem, as they were considered during the final design calculations.
CTE Wind Civil Engineering is an international engineering consulting firm specialized in the analysis and design of on- and nearshore wind turbine foundations. CTE Wind is active in the wind energy sector since 2003 with offices in France (HQ), Brazil, Poland, Portugal, Spain and in Vietnam. CTE Wind has calculated and designed foundations over 16’500 turbines in 70 countries.
CTE Wind R&D and Consulting services are the first choice when it comes to foundation design regardless of the WTG-manufacturer, model, size, power or soil conditions. Thanks to internal R&D-Team with senior engineers, holding over 100 years of cumulated experience in the design of wind turbine foundations, nothing is impossible.
La Richardais (FRA) – In 2019 Developers worldwide have globally commissioned a little over 45GW of onshore wind turbines. According to Bloomberg New Energy Finance, the Danish firm Vestas remained this way the world’s leading wind turbine supplier, with Spanish-German wind engineering company Siemens Gamesa a strong second. Chinas manufacturer number one Goldwind was third in the rankings, while US-Leader GE Renewable Energy’s secured its fourth place. Together the top four manufacturers accounted for 55 percent of the market share.
100 years of cumulated experience
This statement applies more or less also to CTE Wind, which calculated, designed and evaluated about 5000 WTG-foundations in 2019 around the globe. Thanks to CTE Wind’s internal R&D, with senior engineers holding over 100 years of cumulated experience in the design of wind turbine foundations worldwide, new turbine models from the top manufacturers as well as less common WTG-models from smaller or local manufacturers are only a little challenge. CTE Wind engineering services lead to state-of-the-art foundation solutions for wind turbines. Regardless of whether it is a prototype, such as GE’s giant 12 MW Haliade X or smaller 1 MW machine, from German ENO or Dutch EWT.
mentioning: the different types of towers for wind turbines. Concrete (hollow
foundation) and steel towers are well known to CTE Wind. Both tower systems are
suitable to be used alone or in combination. Even foundations with wooden
towers were calculated and designed by CTE Wind in the past.
The sum of all experiences made during the
projects since 2003 is the reason why their engineering services in foundation
design are the first choice for wind turbine manufacturers, wind park
developers and EPC contractors worldwide.
RAWI FORUM 2020 – Over 300+ participants are expected. (Source: RAWI)
We are pleased to announce our participation at RAWI FORUM 2020, taking place from February 19th to 20th in Moscow, Russia. Over 300+ participants are expected.
BUILDING A NEW INDUSTRY TOGETHER
CTP Director and Senior Engineer Dariusz KRASOWSKI and CTE Wind International Business Developer Sergio CARÈ-LUCAS will attend the most important Russian forum to discuss about key trends of wind energy market in Russia. This is a great opportunity for interested companies and experts to meet our dedicated sales team to learn more about CTE Wind’s civil engineering and foundation expertise and to talk about future business opportunities.
ARRANGE A MEETING NOW
Please do not hesitate to write us to arrange a meeting. We are looking forward to meeting you in Moscow. Please contact us here
In the last 2 years over 50 project developers trusted CTE Wind’s Soft-spot® solution. Recently in Spain the expert of wind turbine foundations has won their third project, where the Soft-spot® solution was implemented.
Bilbao (Esp) / La Richardais (FRA) – CTE Wind Ibérica has won again a contract in Spain to calculate and design foundations with its Soft-spot® solution. This is an important milestone for CTE Wind International as now three wind farms on the Iberian Peninsula will take advantage of its cost saving design. In addition to these projects, CTE Wind’s clients are also adopting this solution in many other wind farms worldwide. Argentina, Brazil, Chile, France, Lithuania, Indonesia, Mexico, the Netherlands, Russia, Serbia, Sweden and Thailand to name a few. Over 50 wind farms around the globe, 750 wind turbines are using this resource saving solution which was introduced a while ago by CTE Wind.
« CTE Wind is proud of the confidence shown by its clients, and especially of the interest on applying the Soft-spot® solution», Chief executive Alexander MARTIN said and added « Our design provides interesting advantages and cost saving in material consumption and civil works while being easy to be built. »
Simply the most economical foundation
The Soft-spot® was developed by CTE Wind’s engineering team and is implemented in various countries around the world. As a result of his astonishing design this solution allows savings in concrete volume up to 15%, reduction of foundation diameter and total weight reduction of reinforcement bars of 7 to 9%. The earthwork to be handled is reduced too. In some cases, what is also important is the available space : with Soft-spot® you need less surface for the foundation. The construction is very easy and the material for the soft layer can be easily purchased for a low price all over the world.
CTE Wind Vietnam has been awarded with its 3rd nearshore project. To this day, the Vietnamese expert in foundation design has calculated 27 nearshore wind turbine foundations.
Hanoi (VNM) /La Richardais (FRA) – CTE Wind International branch office in Vietnam (CTV) captures the spirit of the times with its new design for nearshore foundation for wind turbine generator. With its 3rd project in the intertidal zone in Mekong delta of Vietnam CTV won again the customers’ trust. This is already the 3rd project since 2019. With 18 wind turbines and a total power 75MW this project has increased the total of final designs made by CTV to 27. The other two nearshore projects are located in theThanh Hai and in Vung Tau provinces.
New design allows up to 30 % savings
All CTE Wind’s nearshore foundation designs allow to save 30 percent of the construction costs compared to similar projects due to the astonishing design. For the 4.1 MW machines CTE Wind Vietnam has designed a foundation with 550m3 of concrete, 120 tons of steel and 44 piles. The piles have an average length of 60 meters and are hammered into the muddy nearshore underground. In fact, the geotechnics were very challenging and the piles were also designed in-house to withstand tides, waves and ship movements close to the platforms.
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