LATTICE TOWER Gaia-Wind 11 kW Turbine - Segencatalogue.segen.co.uk/reseller/docs/GW-UK-22 REV 2 Foundation... · LATTICE TOWER Gaia-Wind ... • It is compulsory that anybody involved

FOUNDATION MANUAL - LATTICE TOWER

Gaia-Wind 11 kW Turbine

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GW-UK-22 Foundation Manual - Lattice Tower Issue Number: 2

Date of Issue: 29th Jan 2010

Your own

Wind Turbine

Copyright © 2009 Gaia-Wind Ltd. 1 Ainslie Road Hillington Park

Glasgow G52 4RU United Kingdom

Tel: +44 (0) 845 871 4242

E: [email protected]

Document Ref number: GW-UK-22 Foundation Manual - Lattice Tower

Date of Original Issue: August 2008

Issue Number: 2

Date of Revised Issue: 29th January 2010

All illustrations and photographs Copyright © Gaia-Wind Ltd.. No part of this manual may be transmitted into any form by any means without permission from Gaia-Wind Ltd. The information given in this user manual is believed to be accurate and reliable at time of printing. However, Gaia-Wind Ltd. Accepts no liability for the details contained herein. All specifications are subject to change without prior notice.

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GW-UK-22-0110 Foundation Manual - Lattice Tower Issue Number: 2 Date of Issue: 29th Jan 2010

Table of Contents

Health and Safety Information ......................................................................... 4

Foundation Kits................................................................................................. 5

SUPPLIED BY GAIA-WIND ................................................................................... 5

TO BE PROVIDED BY THE INSTALLER .................................................................... 5

TOOLS AND PLANT REQUIREMENTS ..................................................................... 6

1. Introduction ............................................................................................... 7

2. Excavation and Mesh Installation ............................................................ 8

2.1. LOCATION ............................................................................................. 8

2.2. EXCAVATION ......................................................................................... 8

2.3. EARTH CONNECTION AND CABLING .......................................................... 9

2.4. LEVEL AND COMPACT ........................................................................... 10

2.5. STEEL MESH INSTALL ........................................................................... 10

3. Tower Base Installation .......................................................................... 12

3.1. STEEL FOUNDATION FRAME .................................................................. 12

3.2. LEVELLING .......................................................................................... 13

3.3. MOUNT CONTROLLER STAND ................................................................ 13

3.4. CASTING CONCRETE ............................................................................ 14

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Health and Safety Information

• It is compulsory that anybody involved in the construction wear

appropriate personal protective equipment at all times;

including, but not limited to, a high visibility jacket, hard hat, and

safety boots.

• All workers involved in installation must be fully briefed on the

sequence of operations before commencement. This is to

include the identification of danger areas that must not be

occupied.

• Existing site factors, e.g. overhead or underground electric

cables should be identified and an exclusion zone set.

• Temporary signs, notices, and barriers should be erected.

• Structural and mechanical installation must be actively

managed and supervised by a suitably experienced and

competent person.

Gaia-Wind strongly recommends that the foundation

installation be carried out by adequately trained and

experienced personnel. Ensure that these

instructions are read thoroughly and understood. It

is essential that they are retained, along with the

remainder of the manual, as they contain important

safety information that must be adhered to.

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Foundation Kits

Supplied by Gaia-Wind

Quantity Part Description Drawing Position

Size (mm)

1 Controller Cabinet Stand

8800 2700 x 600 x 50

1 Lattice Tower Foundation with Pouring Frame

2057 x 2057 x 1176

To be provided by the Installer

Quantity Part Description Drawing Position

Size (mm)

1 Coil of 16 Gauge Tying Wire

N/A 75 m (length)

8 Reinforcement Mesh (12mm diameter main & cross)

84.0

Shape Code A393 4800 x 2400

104 U-Braces

84.2

Shape code 13 Bar diameter 12 mm A =400 mm B = 140 mm C = 400 mm Overall bar length = 850 mm

104

U-Braces

84.3

Shape code 21 Bar Diameter 12 mm A = 400 mm B = 250 mm C = 350 mm Overall bar length = 1000 mm

1 Coil of 16 Gauge Tying Wire

N/A 75 m (length)

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8 Reinforcement Mesh (10mm diameter main & cross)

84.0

Shape Code A393 4800 x 2400

4 Earth Rods N/A M16 x 1000

1 Earth Wire N/A 25mm2

6 Single Cover Concrete Spacers

N/A Height: 50mm

Concrete

Strength Class: 30 MPa Max. Gravel Content: 32 mm Water/Cement: 0.55 Quantity: 16 m

3 (aprox.)

Tools and Plant Requirements

The provision of all suitable tools and plant are the responsibility of the

individual contractor.

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1. Introduction

This guide outlines the procedures relating to the installation of the

foundations for a Gaia-Wind 11kW wind turbine with a Lattice tower.

Please ensure that this document is read thoroughly prior to

commencing the foundation installation and pay specific attention to the

health and safety guidelines on the opening page. We would also

strongly advise that this document is retained for future reference.

The Foundation Kits consist of the bespoke parts for the assembly of

the required steel work. Page 5 of this document catalogues the

contents of the Foundation Kits. These are divided into two sections;

bespoke parts supplied by Gaia-Wind, and parts that are to be supplied

by the contracted installer. It should be ensured that all parts are

accounted for prior to commencing with the installation.

Provided are details and step-by-step instructions concerning the

excavation, earth connection, and steelwork assembly, with specific

reference to the Foundation Specification Drawings that are attached to

this document.

It remains the responsibility of the contractor to ensure that the

foundation work is complete and acceptable standard and to exact

requirements of the Gaia-Wind foundation specifications. Should there

be any additional queries or comments please contact Gaia-Wind.

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2. Excavation and Mesh Installation

2.1. Location

The precise location for the installation of the wind turbine foundations

will be dependent on that outlined in the approved planning application.

It must be ensured that prior to the commencement of any work that the

exact location of the foundations exactly matches that of the detailed in

the planning consent.

2.2. Excavation

The excavation for the turbine base

requires a volume of approx. 29

cubic meters; that is 5 m length and

breadth, and 1.15 metres in depth.

The ground should be levelled, and

all large rocks removed from the

excavated dig.

In adittion It is required that a cable

trench is excavated, leading away

from the hole.

The trench will be used for the laying

of electrical power cables.

It is required that the trench is at least 750 mm in depth. The exact

positioning, direction, and length of this trench will be site specific.

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2.3. Earth Connection and Cabling

The dedicated turbine earth connection

requires digging a small channel for the

running of the earth cables.

This channel should form the outline of

a square on the inside of the excavated

hole - 1 metre in from the outside walls

and approximately 100 mm in depth.

Four earth rods should be hammered

into the ground at each

corner.

Interconnect the earth

rods with 25mm2 bare

copper wire using rod to

cable clamps to secure.

Attach separate sheathed

earth wires to two of the

earth rods. These earth

wires will protrude from

the finished foundation

and be attached to the

tower base during the turbine installation. It should be ensured that the

wire is sufficiently long for this to be achieved - approx. 2 metres.

The earth wire channel should be backfilled with earth.

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2.4. Level and Compact

Prior to advancing with the installation of the steelwork it should be

ensured that the base of the foundation excavation is suitably levelled

and that all obstructions are removed.

The earth at the base of the foundation should be suitably compacted

as site conditions dictate.

2.5. Steel Mesh Install

The foundation steelwork must be

raised 50mm above the base of the

excavation.

This can be achieved with spacers

spread evenly across the excavated

area.

Assemble the three layers of mesh.

Use the U and Z-Braces to hold the

three layers a mutual distance apart,

as detailed in the foundations

specification drawings – see ‘UK

Lattice Tower Foundation’.

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Ensure that all U and Z braces are

securely fastened to each layer of

mesh using sufficient tying wire.

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3. Tower Base Installation

3.1. Steel Foundation Frame

If the foundation steelwork

is not assembled on

delivery, assemble

maintaining dimensions in

drawing P0000105.

Taking care not to alter the set critical dimensions lift the steelwork into

position over the reinforcement mesh so that the threaded rods extending

from the feet contact good bearing

surfaces, e.g. concrete blocks.

Ensure the steelwork is centred with

the reinforcement mesh.

Ensure a balanced lift using

appropriately rated and tested lifting

tackle.

Ensure threaded rods are supported with a good bearing surface.

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3.2. Levelling and Height Adjustment

It must be verified that the foundation steelwork is appropriately level

before continuing with the installation.

Place a spirit level across the top of the steelwork to check the level of the

steelwork. Adjust the threaded rods extending from the feet to ensure

that all corner flanges are level. Also ensure that the height of the flanges

is as per drawing P0000105.

3.3. Mount Controller Stand

Locate the control box stand.

The control box stand should be placed onto

the mesh according to the foundation

specification drawings.

The stand should be secured to the mesh with

tying wire.

Additionally the stand can be strapped or

pegged into the ground. This will avoid

movement whilst the concrete is curing.

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3.4. Casting Concrete

Firstly, ensure that the earth wire is

secured against the top of the

assembled steelwork. It is vitally

important that the earth wire is not

embedded into the concrete.

Ensure once more that the steelwork

has been assembled exactly according

to the foundation specification drawings

and suitably plumb and level.

The grade of concrete should match

that according to the attached

foundation specification.

Concrete should be poured into the

foundation base, 5m x 5m x 0.55m.

The concrete should be vibrated using

a vibration poker for the removal of air

is pockets. This is essential for the

concrete to achieve full strength and

therefore durability.

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Gaia-Wind Ltd, 1 Ainslie Road, Hillington Park, Glasgow G52 4RU. Tel: +44 (0) 845 871 4242, E: [email protected]

Gaia-Wind document reference: GW-UK-22 Foundation Manual - Lattice Tower. Website: www.gaia-wind.co.uk

www.gaia-wind.co.uk

1826CTR-CTR

1826CTR-CTR

CTR-CTR2692

1756CTR-CTR

2483CTR-CTR

1756CTR-CTR

87.7°4 PLACES

87.7°4 PLACES

(POURING FRAME HIDDENFOR CLARITY)

(NOTE 4)

310

1

8

2

45

7

6

9

(192)

LOWER HOLE

SCALE 1 : 2

SEE NOTE

DETAIL X

2&3

A

CONCRETE BOTTOM LEVEL

4. HOLE SPACING IS GOVERNED BY THE POURING FRAME.3. DATUM A IS TO BE WITHIN 0.1 DEGREES OF LEVEL.

1 HEX HEAD NUT ISO 4033 M16-8Z-tZn 8

9 0170010 - PLAIN WASHER ISO 7089 M10 - 200 HV-tZn

LOWER HOLE (TOP FACE).

0168163

5. WEIGHT IN BRACKETS INCLUDES POURING FRAME AND FASTENERS.

GROUND LEVEL

2. DATUM A PASSES THROUGH THE CENTERS OF EACH FOUNDATION LEG'S FOOT FLANGE THREADED ROD AND NUTS.OF EACH LEG AND THEREFORE DATUM A'S LEVEL CAN BE ADJUSTED USING THE M16 1. PLACE THIS FOUNDATION STEELWORK ONTO A GOOD BEARING SURFACE(S). THE HEIGHT

READ THIS DRAWING IN CONJUNCTION WITH GAIA-WIND DRAWING LAL-1060-02.

NOTES:

- THREADED ROD ISO 898-1 M16x300-8.8-tZn 4

8

10

CONCRETE TOP LEVEL

ITEM NO. PART NO. REVISION DESCRIPTION

WITH POURING FRAME/

QTY.

1 2081010 - FOUNDATION LEG 4

2 2082010 1 FOUNDATION LEG BRACE 4

3 0141030 - HEX HEAD SCREW ISO 4017 M10x30-8.8-tZn 8

4 0181010 - HEX HEAD NUT ISO 4033 M10-8Z-tZn 8

5 2083010 - POURING FRAME 1

6 0142500 - HEX HEAD SCREW ISO 4017 M24x100-10.9-tZn 12

7 0182024 - HEX HEAD NUT ISO 4033 M24-10Z-tZn 12

8 0181016

ZONE REV. DESCRIPTION DRAWN APPV'D DATE

REVISIONS

- 0 FIRST ISSUE DJL PJR 14/10/2009

A

8

SEE NOTE 1

A X

123

450

550

883

2057 TYP

310

WEIGHT (kg):

FILENAME: P0000105.SLDDRW

0

ISO2768-mK

12

H

G

F

E

D

C

B

A

J

K

L

M

N

P

Q

R

A

B

C

D

E

F

G

H

J

K

L

M

N

P

1110987654321 13 14 15 16 17 18 19 20 21 22 23 24

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

TOLERANCES

DRAWN

CHK'D

APPV'D

FINISH:

NAME DATE

MATERIAL:

TITLE:

DWG NO.

-

DJL

PJR

PJR 14/10/2009

13/10/2009

14/10/2009

THIRD ANGLE PROJECTION

DEBUR AND BREAK SHARP EDGES

DO NOT SCALE DRAWING

FOUNDATION INSTALLATION (18M)

P0000105

136

- A0SHEET 1 OF 1SCALE:1:10

REVISIONCOPYRIGHT © 2009 GAIA-WIND LTD

Documents

LATTICE TOWER Gaia-Wind 11 kW Turbine - Segencatalogue.segen.co.uk/reseller/docs/GW-UK-22 REV 2 Foundation... · LATTICE TOWER Gaia-Wind ... • It is compulsory that anybody involved