A company of GRI Renewable Industries
Corporación Gestamp
The strength of a Business Group Corporación Gestamp is a European multinational leader in the steel service centres, automotive components and renewable energy sectors. Calidad
I+D+i Corporación Gestamp is a European multinational, with a track record of over 50 years and is a leader in steel service centres, automotive components and the renewable energy sectors. It comprises three divisions - Gonvarri Steel Industries, Capacidad Gestamp Automoción and Gestamp Renewables - the holding Industrial is constituted by 140 industrial plants in over 25 Countries throughout Europe, America and Asia. Corporación Gestamp closed 2013 with a turnover of €9 billion. In an effort to encourage sustainable development, the strategic axis underpinning our business is to promote quality management and environmental conservation.
A team of 36.000 industry professionals and employees worldwide is the foundation on which our future growth is laid . Gestamp Renewable Industries (GRI) is backed by the strengths of Corporación Gestamp and its long-term commitment to the renewable energy sector. Through the new division, GRI Hybrid Towers provides customers with comprehensive solutions to enable the optimization of the design, manufacture and execution of new foundations and hybrid tower structures.
Our plants are ISO 9000 and ISO 14001 certified.
Financial Solvency
Industrial Capacity Global Presence
2
R&D+i
Quality
SCM
GRI Renewable Industries
Achieving global leadership in the renewable energies industrial sector GRI Renewable Industries was founded in 2008 and is the renewable energy industrial division of Corporaci贸n Gestamp. GRI Renewable Industries shares the vision of Corporaci贸n Gestamp: leaders in our service, applying continuous improvement, and incorporating technological innovations into all our processes.
Steel Flanges
Wind Services
Steel Towers
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Corporación Gestamp
Presencia global Global operations
Eur 91 17 25.
Norteamérica 10 Plantas Industriales 4 Oficinas Comerciales 1.500 Empleados
GRI Renewable Industries Iraeta GRI Renewable Industries Galicia
GRI Renewable Industries Pernambuco Pernambuco GB Wind Services
Sudamérica 12 Plantas Industriales 2 Oficinas Comerciales 3.000 Empleados 4
GRI Renewable Industries
ropa Plantas Industriales Oficinas Comerciales .000 Empleados
GRI Renewable Industries Bandirma
GRI Shandong Iraeta 1 GRI Shandong Iraeta 2 GRI Shandong Iraeta 3
GRI Renewable Industries Power Gear GRI India
GRI South Africa
Asia 17 Plantas Industriales África GRI´s Wind Towers factories 2 Oficinas Comerciales 2.500 Empleados OficinasGRI´s Comerciales flanges factories
Plantas Industriales GRI Renewable Industries Wind Services Where Corporación Gestamp operates Presencia de Corporación Gestamp Where GRI operates 5
Hybrid Towers
GRI Hybrid Towers offers the wind industry, innovative solutions, that address the challenges posed by new generations of turbines, based on a proven track record in steel manufacturing and the capacity of precast concrete to solve the weaknesses that steel alone is unable to manage. GRI Hybrid Towers unifies GRI´s wide experience in renewable energies and wind towers with the know-how provided by iConkrete in the engineering and manufacturing of precast concrete. GRI´s extensive and professional team has been strengthened by the multidisciplinary iConkrete team, enabling GRI Hybrid Towers to acquire the ability to undertake the entire life cycle of any project.
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GRI Hybrid Towers is an organization with the capacity to span a project´s entire range of activities: design, manufacturing, transportation and assembly of the hybrid towers and their foundations. Our commitment to our customers is to provide them with optimal solutions at any time, backed by product certification and technical support in engineering, offering the best customised and tailor-made solutions for each project. Our commitment to society is to offer an environmentally friendly product.
Services offered
Foundations In collaboration with OEMs and developers, we design a foundation according to our universal patent, which is compatible with each type of tower: either steel, concrete or hybrid, focusing on cost efficiency and reduction of lead times.
Hybrid Tower Supply We design, calculate and produce the most optimized hybrid tower in collaboration with OEMs, customising the tower for each type of wind, location, height, type of machine and blade length. Regarding the steel section, we make use of our extensive experience in steel towers manufacturing provided by GRI Wind Steel. Regarding the concrete section, in addition to designing and optimizing it, we analyze the production constraints, leadtimes, quality, implementation and availability of resources, to design and install the prefabrication plant with all its auxiliary means needed to execute each project.
Executing the foundation
Transport of sections and tower assembly
Once the foundation has been designed and calculated, we can provide supervision or even execute the work. Additionally, if necessary, we can prefabricate the stiffening ribs to shorten lead times.
During the design and calculation of the tower, all the alternatives are considered to optimize the transport and assembly of both the steel and concrete sections.
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Hybrid tower The optimization of investments poses new challenges within the wind industry. The reduction of the â‚Ź/KWh year ratio has led to the development of 10.000 kW 150m more powerful turbines to reduce the economic 5.000 kW 125m impact on the structure and the 3.000 kW 100m infrastructure that 1.800 kW 80m supports them. 1.500 kW 750 kW 50m
70m
300 kW 30m 75 kW 17m 19801990
19901995
19952000
20002005
20052010
20102015
750
Future
Several well-reputed studies coincide that the hybrid tower is the most viable technical and economical alternative to contribute to the expected technological leap.
700 650 Investment â‚ŹMM.....
20152020
600
Weided steel shell Steel shell friction joint Concrete sipformed Hybrid Lattice Wood
550 500 450
50
75
100
125
150
175 (Source ELFORSK report 10:48)
Hub height m
Our hybrid tower concept uses each component in the adequate proportion to optimize the profitability of the tower. Advantages:
1 We solve technical issues at the base of the tower, using staves of concrete up to 50 meters tall without any horizontal joints.
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2 We make use of the experience and economies of scale achieved by the wind industry in the design and manufacture of welded steel tubular sections.
3 The joint between the concrete shaft and the steel section is solved with standard anchor bolts.
4 The segments are prefabricated on site, helping to deal with increasing local content requirements.
The design of our concrete stave enables us to achieve a very flexible system with linear costs. This allows us to install the convenient height per tower and per wind turbine, rising the profit obtained in each project because of increasing incomes and a cost reduction per tower installed.
Foundations GRI Hybrid Towers has developed a new foundation design containing steel and concrete positioned where each material really works optimally, and provides greater efficiency and ductility. The design even allows the prefabrication of the foundation, therefore shortening execution times.
Components of the foundation
Structural response
A circular or polygonal top slab of concrete, designed to distribute pressure evenly over the ground.
We adapt the geometry of the foundation to withstand greater compression in the upper concrete slab and tensile stresses in the lower reinforced rib section by forming a “T�.
A reinforcing central ring just below the tower shaft. Several reinforcing beams or stiffening ribs, together with the upper slab, form a T-shaped composite section.
The smart design of the geometry also allows us to mobilize the ground, with friction contributing to the stability to avoid overturning and sliding. The solution has been run using finite elements modelling tools which take into consideration the foundation, the soil, the interface and the execution and commissioning process.
Comparative Summary The summary brings together the main figures of a real example comparing the conventional foundation with the GRI Hybrid Towers solution. Depending on the power of the wind turbine, the height and type of tower, savings are between 15% and 30%.
Steel tower 80HH 2MW Power
Measurements
Excavation
m
3
Period
Conventional
GHT
Saving
%
Conventional
GHT
Saving
%
815,00
391,73
423,27
51,94%
3,00
1,00
2,00
66,67%
Concrete Cleaning
m
28,00
25,45
2,55
9,12%
1,00
1,00
0,00
0,00%
Concrete Foundation H30
m3
346,00
334,60
11,40
3,29%
1,00
1,00
0,00
0,00%
Concrete Foundation H35
m
7,13
0,00
7,13
100%
1,00
0,00
1,00
100%
Reinforcing
Kg.
29.067,00
15,71%
5,00
4,00
1,00
20,00%
Earthfill
m
433,87
86,83%
1,00
1,00
0,00
0,00%
3
3
3
24.500,00 4.567,00 57,13
376,74
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Execution process
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1. Foundation execution
2. Prefabrication of the tower
The foundation design enables a rapid execution and a high industrialization process.
Simultaneous to the execution of the foundations, on site pre-fabrication takes place eliminating unnecessary assembly delays and costly public road transportation.
3. Start of concrete shaft assembly
4. Installation of the concrete section
Upon reaching the prescribed resistance in the foundation, the assembly of the concrete section takes place.
The absence of horizontal joints allows -staves to be installed with ease and quickly.
5. Completion of the concrete tower and installation of steel sections The internal elements are assembled in the prefabrication plant, and once the last stave is fitted, the concrete section is completed. Immediately after the assembly of the concrete section, the steel sections are fitted. The simplicity and speed of installation of the steel section is backed by Gestamp’s extensive experience acquired in the wind sector.
• Our hybrid tower is designed in an optimized way to achieve a significant cost reduction due to the flexibility the concrete staves provide to the complete tower. • We solve dynamic and transport problems steel towers have. • We can highlight the simplicity of our solution and rapid assembly as part of our strength in comparisson with concrete towers and other hybrid tower solutions. • In May 2014 we obtained the certification of TÜV SUD for our first hybrid tower design and in July we obteined the ISO 9001:2008 for commerzialization, design, development, manufacture and assembly of foundations and hybrid wind towers.
TÜV SÜD Industrie Service GmbH Certification Body Wind Turbines
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c/ OmbĂş 3, 12th 28045 Madrid - Spain Tel.: + 34 91 177 00 10 info@gri.com.es www.gri.com.es
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