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NABRALIFT PILE FOUNDATION
ION AROCENA DE LA RÚAProgram Manager+34 670 366 [email protected]
Bremen, August 27th 2019PPT-1736 Rev. /
2
AGENDA
1. NABRALIFT INTRODUCTION• XXL Tower Challenges• Nabralift Technology
2. NABRALIFT FOUNDATION PORTFOLIO• Foundation Alternatives• Adaptation to Soil Characteristics
3. NABRALIFT PILE FOUNDATION DESIGN• Pile Foundation Design Basis• Cost Savings
4. ONGOING PROJECTS• First Pile Foundation• Nabralift Pipeline Forecast
3
Cost IncreaseExponential Cost
Most Expensive Component HH>120
Installation RatesSlow Wind Farm Installation Rates
Inefficiency Time Increase
Assembly CranesLack of Availability
Large Mobilization and Rental Costs
LogisticsRoads / Bridges Limiting Concepts
High Logistic Cost
WTG IntegrationControl Challenges in Soft-Soft Towers
Soft-Stiff Unfeasible for XXL Steel Tow.
Nabralift Description1 NABRALIFT® INTRODUCTION
6
GAILDORF (ALE) VIINAMÄKI (FIN) RENANIA (ALE) ESLAVA (SPN)178m 175m 164m 160m
Nabralift Description1 NABRALIFT® INTRODUCTION
8
Easy IntegrationSoft-Stiff for HH>180m
Standard Interface
Ultra Low CostFoundation / Tower Components
Logistics / Assembly
Fast AssemblySelf-Erection in 3 days / Prefab Found.
Higher Wind Speeds for Erection
Self ErectionNo Large Cranes
Low Occupation of Small Cranes
Minimum LogisticsSized for Standard Containers
Optimum Packaging
Assembly Platform
Tower Foundation
Tower Components
Tower Logistics
Tower/WTG InstallationTOTAL-22%
160m Standard Steel Tower 160m Nabralift
-50%
-60%
-10%
-30%
-25%
Nabralift Description1 NABRALIFT® INTRODUCTION
9
CO2 Emissions ReductionMassive Concrete & Steel Reduction
Steel
Concrete
Concrete
Steel
-70%
160m Hybrid Tower
Concrete
Steel
160m Nabralift Tower
Foundation
Tower
200 towers/year:
savings equivalent to 120 000 UE-people emissions
Footprint1000m2 reduction of assembly platform
-50%
Removable & recyclable structureSteel to be reused in future structures
Concrete tower waste after demolition Nabralift components after disassembly
Nabralift Description1 NABRALIFT® INTRODUCTION
10
AGENDA
1. NABRALIFT INTRODUCTION• XXL Tower Challenges• Nabralift Technology
2. NABRALIFT FOUNDATION PORTFOLIO• Foundation Alternatives• Adaptation to Soil Characteristics
3. NABRALIFT PILE FOUNDATION DESIGN• Pile Foundation Design Basis• Cost Savings
4. ONGOING PROJECTS• First Pile Foundation• Nabralift Pipeline Forecast
12
Foundation Portfolio
Gravitational FoundationStandard Wind Solution
Deep FoundationsFast & Disruptive Cost
Piled FoundationsStandard Soil
Anchor RockBedrock in Surface
13
Gravitational FoundationStandard Wind Solution
Simple Foundation Interface3x44 studs for 4MW-HH160
Preassembled Bolt CagesFast Installation on Site
Light Steel Reinforcement3x14T steel for 4MW-HH160
Low Concrete Volume40% reduction
14
Technology Basis
• Solution for Wind Turbines• Optimized for Nabralift
10-15m
0-15m
Fast Solution1 week / foundation
Minimum Cost for Hard Rock-50% vs wind rock found.
Anchor RockBedrock in Surface
12-15m
15
Pile FoundationStandard Soil
Technology Basis
• Design: offshore jackets• Process/Cost: civil works
10-15m
0-15m
Fastest Solution4 days / foundation
Minimum Cost-60% vs std wind foundations
16
12%
63%
25%
Gravitational Pile Anchor Rock
P
P
A
P
G
P
P
A
2 NABRALIFT® FOUNDATION PORTFOLIOApplicability as per Real Geotechnical Studies
17
AGENDA
1. NABRALIFT INTRODUCTION• XXL Tower Challenges• Nabralift Technology
2. NABRALIFT FOUNDATION PORTFOLIO• Foundation Alternatives• Adaptation to Soil Characteristics
3. NABRALIFT PILE FOUNDATION DESIGN• Pile Foundation Design Basis• Cost Savings
4. ONGOING PROJECTS• First Pile Foundation• Nabralift Pipeline Forecast
18
Pile Design (4MW-160m)Diameter (D) 1.5mDepth (L) 5MPa Rock 20m
10MPa Rock 15m15MPa Rock 15m
Pile Part List (10MPa Rock)Concrete 80m3
Reinforcement Steel 21TM36 Bolts (1.5m) 132udAnchor cage plates (250kg) 6ud
D
L
Pile Foundation Design3 NABRALIFT PILE FOUNDATION
19
Materials & Equipments3 NABRALIFT PILE FOUNDATION MANUFACTURING PROCESS
Pile Reinforcement
Auxiliary Digger Kelly
Auxiliary Crane (60T)
Bolt Cages
Concrete
20
3 NABRALIFT PILE FOUNDATION
1.-Drilling5MPa Rock 6h10MPa Rock 8h15MPa Rock 15h
Pile Foundation Manufacturing Process
21
3 NABRALIFT PILE FOUNDATION
2.-Reinforcement Installation2h/pile
Pile Foundation Manufacturing Process
25
3 SUMMARY OF SAVINGSMaterial Savings
0
20
40
60
80
100
120
140
0
100
200
300
400
500
600
700
NBW Pile Foundation NBW Grav. Foundation Standard Foundation
Mas
s [T
]
Volu
me
[m3]
4MW-HH160 Foundation ComparisonConcrete Volume [m3] Reinforcement Steel [T]
26
3 SUMMARY OF SAVINGSCost Savings
0%
25%
50%
75%
100%
4 6 8 10 12 14 16
Cos
t vs
Stan
dard
Fou
nd [%
]
Rock Compressive Strength [MPa]
Foundation Cost ComparisonNBW Pile Foundation NBW Grav. Foundation Standard Foundation
27
AGENDA
1. NABRALIFT INTRODUCTION• XXL Tower Challenges• Nabralift Technology
2. NABRALIFT FOUNDATION PORTFOLIO• Foundation Alternatives• Adaptation to Soil Characteristics
3. NABRALIFT PILE FOUNDATION DESIGN• Pile Foundation Design Basis• Cost Savings
4. ONGOING PROJECTS• First Pile Foundation• Nabralift Pipeline Forecast
28
1 x 4.5MW - HH1671 x 4.5MW - HH200
1 x 3.6MW - HH144
2018 2019 2020 20211 x 3.5MW - HH160
4 ONGOING PROJECTS NABRALIFT INSTALLATION PIPELINE
30
Pile Design (3.6MW-144m)Diameter (D) 1.2mDepth (L) 4MPa Rock 24m
Pile Foundation Part ListConcrete 81m3
Reinforcement Steel 25TM36 Bolts (1.5m) 99udAnchor cage plates (250kg) 6ud
4 ONGOING PROJECTS FIRST PILE FOUNDATION
Detailed Design in Collaboration with
35
CONCLUSIONS
NabraliftEntry-into-Market Phase
Pile FoundationDisruptive Installation Pace (4 days)
Pile FoundationDisruptive Cost Reduction (-60%)