Hybrid FRP-concrete-steel prestressed double-skin wind turbine towers: Concept,design considerations and research needs

Abstract

The past decade has seen rapid development of offshore wind energy around the world. Furthermore, to improve the efficiency of power generation, wind turbine development has been trending towards increasingly large and tall turbines. These developments call for innovations in the form of wind turbine towers to address the challenges faced by existing tower forms (e.g., steel tubular towers and prestressed concrete towers) in structural adequacy, construction efficiency and/or maintenance. This paper presents a new form of hybrid wind turbine towers which possesses many important advantages over the existing tower forms and are particularly suitable for large offshore wind turbines. The new hybrid towers, termed herein hybrid FRP-concrete-steel prestressed double-skin wind turbine towers or PDSWTs, are prefabricated in segments and then assembled on site. The PDSWT segments are a variation of hybrid FRP-concrete-steel double-skin tubular members (DSTMs), and they consist of an outer confining tube made of fibre-reinforced polymer (FRP), a thin steel inner tube with welded shear studs, prestressed concrete between the two tubes, and flanges welded at the ends of the steel tube. The onsite assembly of the tower involves mainly connecting the steel flanges of two adjacent segments using high-strength bolts, and installing prestressed tendons through the whole tower. In this paper, the rationale behind the development of PDSWTs is first explained, followed by a discussion of the design considerations and future research needs to facilitate the practical applications of the new tower form.

Keywords

offshore wind turbine towers fibre-reinforced polymer double-skin tubular members confined concrete

Get full access to this article

View all access options for this article.

References

ACI (American Concrete Institute) (2017) Guide for the Design and Construction of Externally Bonded FRP Systems for Strengthening Concrete Structures (ACI-440). New York, NY: Detroit.

Apex Tech (2023) Vertical type GRP tank filament winding machine. [Online image] https://www.apextechltd.com/product-vertical-type-grp-tank-filament-winding-machine.html

Balkos

Sjaarda

West

, et al. (2019) Static and fatigue tests of steel-precast composite beam specimens with through-bolt shear connectors. Journal of Bridge Engineering 24(5): 04019036.

Bernuzzi

Crespi

Montuori

, et al. (2021) Resonance of steel wind turbines: problems and solutions. Structures 32: 65–75.

Bilgili

Alphan

(2022) Global growth in offshore wind turbine technology. Clean Technologies and Environmental Policy 24(7): 2215–2227.

CEB-FIP (International Federation for Structural Concrete) (2013) Fib Model Code for Concrete Structures 2010 (Fib Model Code 2010). Lausanne, Switzerland: CEB-FIP (International Federation for Structural Concrete).

China Architecture and Building Press (2010) Code for Design of Concrete Structures. Beijing, China: China Architecture and Building Press. GB 50010.

China Architecture and Building Press (2016) Code for Design of Composite Structures (JGJ138). Beijing, China: China Architecture and Building Press.

China Architecture and Building Press (2020) Technical Specification for Concrete-Filled Double Skin Steel Tubular Structures (T/CCES 7). Beijing, China: China Architecture and Building Press.

10.

China Electric Power Press (2018) Code of Prestressed Precast Concrete Tower for Wind Turbine (T/CEC 5008). Beijing, China: China Electric Power Press.

11.

China Planning Press (2019) Standard for Design of High-Rising Structures (GB 50135). Beijing, China: China Planning Press.

12.

China Planning Press (2020) Technical Standard for Fiber Reinforced Polymer (FRP) in Construction (GB 50608). Beijing, China: China Planning Press.

13.

CSSC Hai Zhuang Wind Power Co (2023) The First 165-meter Lattice Tower in China Was Successfully Installed. Chongqing, China: CSSC Hai Zhuang Wind Power Co. [Online image] https://www.cssc-hz.com/?News/HotNews/149.html

14.

Damiani

(2016) 10 - design of offshore wind turbine towers. In: Offshore Wind Farms. Cambridge, UK: Woodhead Publishing, 263–357.

15.

de Lana

Magalha

PAA

Magalhaes

, et al. (2021) Behavior study of prestressed concrete wind-turbine tower in circular cross-section. Engineering Structures 227: 111403.

16.

DNV (Det Norske Veritas) (2014) Design of Offshore Wind Turbine Structures (DNV-OS-J101). Oslo, Norway: Det Norske Veritas.

17.

DNV GL (Det Norske Veritas & Germanischer Lloyd) (2016) Loads and Site Conditions for Wind Turbines (DNV-ST-0437). Oslo, Norway: Det Norske Veritas.

18.

DNV GL (Det Norske Veritas & Germanischer Lloyd) (2019a) Fatigue Design of Offshore Steel Structures (DNV-RP-C203). Oslo, Norway: Det Norske Veritas.

19.

DNV GL (Det Norske Veritas & Germanischer Lloyd) (2019b) Buckling Strength of Shells (DNV-RP-C202). Oslo, Norway: Det Norske Veritas.

20.

DNV GL (Det Norske Veritas & Germanischer Lloyd) (2021) Support Structures for Wind Turbines (DNV-ST-0126). Oslo, Norway: Det Norske Veritas.

21.

Eurocode (2004) Eurocode 4: Design of Composite Steel and Concrete Structures - Part 1-1: General Rules and Rules for Buildings (EN 1994-1-1:2004). Brussels: European Committee for Standardization.

22.

Eurocode (2005) Eurocode 3: Design of Steel Structures - Part 1-9: Fatigue (EN 1993-1-9:2005). Brussels: European Committee for Standardization.

23.

Excel Pipes (2023) Pipe joints and coupling. [Online image] https://excelpipes.com/pipe-joints-and-fittings/

24.

Gencturk

Attar

Tort

(2015) Selection of an optimal lattice wind turbine tower for a seismic region based on the Cost of Energy. KSCE Journal of Civil Engineering 19(7): 2179–2190.

25.

Goldwind Science & Technology Co (2022) The New Standard of the Prestressed Concrete Tower Is Implemented to Make the Wind Turbine Higher and More Stable. Beijing, China: Goldwind Science & Technology Co Ltd. https://www.goldwind.com/cn/news/focus-article/?id=711247482931378176

26.

Han

Tao

Liao

, et al. (2010) Tests on cyclic performance of FRP-concrete-steel double-skin tubular columns. Thin-Walled Structures 48(6): 430–493.

27.

Hanswille

Porsch

Ustundag

(2007) Resistance of headed studs subjected to fatigue loading: Part I: experimental study. Journal of Constructional Steel Research 63(4): 475–484.

28.

Yang

Baniotopoulos

, et al. (2020) Dynamic analysis of offshore steel wind turbine towers subjected to wind, wave and current loading during construction. Ocean Engineering 216: 108084.

29.

Huang

Zhou

, et al. (2022) Geometric optimisation analysis of Steel-Concrete hybrid wind turbine towers. Structures 35: 1125–1137.

30.

HUASTRO Energy Technology Co., Ltd. (2022) 170 meters high: the highest lattice steel wind tower in the world. [Online image] https://huastro.com/show-9-17-1.html

31.

Huo

Tong

(2020) An approach to wind-induced fatigue analysis of wind turbine tubular towers. Journal of Constructional Steel Research 166: 105917.

32.

IEA (2019) World energy outlook 2019. https://www.iea.org/reports/world-energy-outlook-2019/

33.

IEA (2023) World energy outlook 2023. https://www.iea.org/reports/world-energy-outlook-2023/

34.

Klein

Marx

(2021) Torsional load-bearing capacity of half-shell segments for prestressed concrete towers. Engineering Structures 243: 112589.

35.

Koulatsou

Kazakis

Gantes

, et al. (2020) Resonance investigation and its effects on weight optimization of tubular steel wind turbine towers. Procedia Manufacturing 44: 4–11.

36.

Liu

Zhou

Wang

, et al. (2023) Seismic behavior of prestressed concrete filled steel tubular lattice tower subjected to combined compression-bending-torsion. Journal of Constructional Steel Research 204: 107883.

37.

Luo

Qiu

(2021) An anti-fatigue design method for a novel latticed prestressed anti-fatigue wind turbine tower structure. Progress in Steel Building Structures 23(05): 73–81, (in Chinese).

38.

Melchers

(2005) The effect of corrosion on the structural reliability of steel offshore structures. Corrosion Science 47(10): 2391–2410.

39.

Zeng

Liao

, et al. (2022) Flexural behavior of hybrid FRP-concrete-steel double-skin tubular beams with PBL shear connectors. Engineering Structures 254: 113840.

40.

Myers

Arwade

Valamanesh

, et al. (2015) Strength, stiffness, resonance and the design of offshore wind turbine monopiles. Engineering Structures 100: 332–341.

41.

Newberry

(2001) Large diameter FRP tanks mark progress in Mexico. Reinforced Plastics 45(11): 40–42.

42.

Pacheco

Pimenta

Pereira

, et al. (2022) Fatigue assessment of wind turbine towers: review of processing strategies with illustrative case study. Energies 15(13): 4782.

43.

Parashar

Mertiny

(2012) Adhesively bonded composite tubular joints. International Journal of Adhesion and Adhesives 38: 58–68.

44.

Stavridou

Koltsakis

Baniotopoulos

(2020) Lattice and tubular steel wind turbine towers. Comparative structural investigation. Energies 13(23): 6325.

45.

Teng

(2011) Hybrid FRP-concrete-steel double-skin tubular members : concept, behaviour and design. Proc., International Conference on Thin-Walled Structures 99–110.

46.

Teng

Wong

(2004) Behaviour of hybrid FRP-concrete-steel double-skin tubular columns. In: Proceedings, 2nd International conference on FRP composites in civil engineering, Adelaide, Australia, 8-10 December 2004, 811–818.

47.

Teng

Wong

, et al. (2007) Hybrid FRP-concrete-steel tubular columns: concept and behavior. Construction and Building Materials 21(4): 846–854.

48.

Teng

Lin

(2012) FRP (Fiber Reinforce Plastic) Tube-Concrete-Steel Tube Combined Tube Tower and Segmented Construction Method Thereof (China Patent No. ZL200910247112.6). Haidian, Beijing: National Intellectual Property Administration.

49.

von der Haar

Marx

(2015) Design aspects of concrete towers for wind turbines. Journal of the South African Institution of Civil Engineers 57: 30–37.

50.

Wang

Han

Tao

(2015) Behavior of FRP–concrete–steel double skin tubular members under lateral impact: experimental study. Thin-Walled Structures 95: 363–373.

51.

Wang

Liu

, et al. (2020) Experimental investigation of the hybrid FRP-UHPC-steel double-skin tubular columns under lateral impact loading. Journal of Composites for Construction 24(5): 04020041.

52.

Gao

WB, G

Wang

, et al. (2009) The winding machine system of large diameter FRP tank. In: Proc., 2009 international conference on mechatronics and automation, Changchun, China, 9-12 August 2009, 1273–1278.

53.

Yao

Jiang

, et al. (2015) Experimental investigation on large-scale slender FRP-concrete-steel double-skin tubular columns subjected to eccentric compression. Advances in Structural Engineering 18(10): 1737–1746.

54.

(2007) Behavior of Hybrid FRP-Concrete-Steel Double-Skin Tubular Columns. Hong Kong, China: The Hong Kong Polytechnic University. PhD Thesis.

55.

Wong

Teng

, et al. (2006) Flexural behaviour of hybrid FRP-concrete-steel double skin tubular members. Journal of Composites for Construction 10(5): 443–452.

56.

Wong

Teng

(2010) Behavior of hybrid FRP-concrete-steel double-skin tubular columns subjected to eccentric compression. Advances in Structural Engineering 13(5): 961–974.

57.

Zhang

Huang

, et al. (2017) Compressive behavior of hybrid double-skin tubular columns with a large rupture strain FRP tube. Composite Structures 171: 10–18.

58.

Zhang

Wang

(2022) Development of offshore wind power and foundation technology for offshore wind turbines in China. Ocean Engineering 266: 113256.

59.

Zhang

Teng

(2015) Experimental behavior of hybrid FRP-concrete-steel double-skin tubular columns under combined axial compression and cyclic lateral loading. Engineering Structures 99: 214–231.

60.

Zhang

Teng

(2017) Compressive behavior of double-skin tubular columns with high-strength concrete and a filament-wound FRP tube. Journal of Composites for Construction 21(5): 04017029.