concrete towers - a business case for sustained investment_rev 5
TRANSCRIPT
Concrete Towers - a business case for sustained local investment
CONCRETE GROWTHconcrete materials engineers
Santie Gouws Specialist Consultant –Concrete Materials EngineeringDirector –Concrete Growth
Concrete Towers – a business case for sustained investment (I)
CONCRETE GROWTHconcrete materials engineers
Relevance of Concrete Towers (I)
Global Development of Turbine Capacity
and Tower Height
IPCC – Intergovernmental panel on climate change 2011
CONCRETE GROWTHconcrete materials engineers
onshore
onshore
Offshore Offshore
Relevance of Concrete Towers (II)
US Wind Potential Capacity at 140m hub
height – published late 2014
CONCRETE GROWTHconcrete materials engineers
Relevance of Concrete Towers (III)
South Africa’s first wind farms 2013-2013
• Hub height 80 to 100m, turbine capacity 2 to 3 MW
• Concrete towers cost effective from 90m
• Concrete towers – ‘local’ by their very natureCONCRETE GROWTHconcrete materials engineers
onshore
onshore
Offshore Offshore
Relevance of Concrete Towers (IV)
• Acciona Windpower’s Gouda towers
• Local Investment
• Benefits achieved
CONCRETE GROWTHconcrete materials engineers
Acciona Windpower’s Concrete Towers (I)
• Patented precast concrete tower design,
complete with engineering drawings and
manufacturing specifications
• 100m and 120m hub heights available
• Developed in-house and commercialized over
the past 8 years
• Reproduced internationally through use of local
contractors without the need for specialized
labour or equipment
• Rolled out in Spain, Brazil, Mexico, Poland
• Now also in
South Africa
• 250 towers to
date
CONCRETE GROWTHconcrete materials engineers
Acciona Windpower’s Concrete Towers (II)
Gouda Wind Farm – South Africa
• 46 towers with 100m hub height
• 5 cylindrical 20m concrete sections per tower
• 2 - 4 precast concrete segments per 20m section
• 17 precast concrete segments per tower
• 782 segments in total from 5 moulds ~ 16 500 m3
• ~ 60t per segment
• Manufactured in CT
• Transported 100 km
to Gouda site
• On site assembly
CONCRETE GROWTHconcrete materials engineers
Investment into Localization (I)
Key Local Role Players for Gouda
• Concrete Units (SA) with engineering input from
Windtechnic (Spain) – precast manufacture
• Argent - Megamix - concrete
• RSC and Steeledale - reinforcement
• Afrisam - aggregates
• PPC Cement – cement
• BASF SA - admixture
• Absolute Rigging - transport
• B D Materials – grouting contractor
• Sika SA – grout/epoxy sealant/chord
• Concrete Growth – quality management of
precast manufactureCONCRETE GROWTHconcrete materials engineers
CONCRETE GROWTHconcrete materials engineers
Investment into Localization (II)
Precast capability base prior to the project
• Peak production and logistics
management rate ~ 500m3/week
• Under-roof factory ~ 3000m2
• Open-air factory area ~ 10 000m2
• Handling equipment
• 100t gantry crane
• 10t reinforcing gantry
• Production staff ~ 50/month
• Steel reinforcing tensile
strength of 450MPa
• Concrete design strength of
50MPa
• Normal vibrated concrete
CONCRETE GROWTHconcrete materials engineers
Investment into Localization (III)
Manufacturing requirements for Gouda
• 10 month manufacturing period ~ peak 650m3/w
• Structural concrete to European Standards
• Steel Reinforcing Tensile Strength 500MPa
• Concrete Design Strength of 75MPa
• Self-compacting concrete, no vibration
• Moulds by AWP,
set up by
contractor
• Dimensional
tolerances
to < 1cm
CONCRETE GROWTHconcrete materials engineers
Investment into Localization (IV)
Factory upgrade by Concrete Units
• Additional under roof area ~ 1100m2
• Handling equipment increased
• Two additional 35t gantry cranes
• Additional 16t reinforcing crane
• Time Frame ~ 10 weeks (during project start-up)
• Financial Investment ~
R12 000 000
CONCRETE GROWTHconcrete materials engineers
Investment into Localization (V)
Investment into people and technology
• Technology transfer through Acciona
Windpower’s ‘Manufacturing Instructions’
• ‘how to’ manual based on Spanish
conditions, materials, methods
• Learning by doing and ‘localizing’
• High strength self-
compacting concrete
• Vertical Joints
• Measuring of performance
by Acciona’s Quality
Management System
Measuring the performance
• Acciona Windpower’s Quality Management
System
Investment into Localization (VI)
CONCRETE GROWTHconcrete materials engineers
Benefits realized (I)
CONCRETE GROWTHconcrete materials engineers
Investment into people
• Quality Management System as measurement
tool
Local expenditure on raw materials
782 segments ~ 97 % local content
Manufacture of Segments
Concrete (material) 16 500 m3 R 30 000 000
Reinforcement 2 800 t R 26 000 000
Post tensioningcable
100 t R 2 000 000
TPA – lifting hooks 6256 nr off R 2 000 000
Metallic ducts 8 300 m R 300 000
Assembly of Segments
Grout 38 t per tower
Benefits realized (II)Jobs created and new skills learnt
(Peak production staff component)
• Engineering component (manufacture)
• 10 persons (4 Spanish)
• Quality management team
• 6 persons
• Total staff component ~ 216 persons
• 48 persons sourced from Gouda
• 25 % of these 48 will be incorporated into
the next project
Learnt to work with high strength self-
compacting concrete
Learnt to work in highly industrialized
precast set-up with strict Quality Control
782 Segments Completed – on time and within budget
Cost and lead-time reductions possible for future wind turbine
tower supply.
Benefits realized (III)
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05-Feb19-Feb05-Mar19-Mar02-Apr 16-Apr 30-Apr14-May28-May11-Jun 25-Jun 09-Jul 23-Jul 06-Aug20-Aug03-Sep17-Sep 01-Oct 15-Oct 29-Oct12-Nov26-Nov10-Dec24-Dec
277 units in 5 months55 units/month
470 units in 3,75 months125 units/month
Peak production rate 650 m3/week
Localization of Acciona Windpower’s
Precast Concrete Tower Technology
INPUT
• Low capital investment and short implementation
phase of factory upgrade
• Training through learning by doing and measuring
OUTPUT
Gouda Wind Farm 46 WTG’s, 3MW on concrete towers
97% local content in tower segments
216 jobs created, some permanent
High skills and technology development in local
precast concrete manufacture industry
Potential for future reduction in cost and lead time
Potential for application of new skills back into local
construction industry
Real risk of loosing skills if investment not sustained
Conclusions