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CUSTOM-MADE DUCORIT FOR STRUCTURAL CONNECTIONS IN TOWERS AND FOUNDATIONS

By Karina Hojgaard, November 30, 2015

Showing a willingness to move with the market and develop new products and solutions, ITW WindGroup has launched a new product series of Onshore Ducorit® material to be used in the assembly process of concrete towers and the undercasting of tower flange connections

The Onshore Ducorit® products consist of high quality materials applicable and approved for onshore structural connections.
This newly developed product series is characterized by a consistent and high quality material which develops a significant early strength. This makes Ducorit® a strong structural component which meets international high design standards and provides grouting companies with a unique and strong solution throughout the grouting process on site.

ITW always works closely with customers when developing new products and solutions and the development of new onshore Ducorit® product series was initiated in response to market demands and to satisfy customers’ needs.

“Our experience and research of grouting onshore showed that we needed to develop a specific product series targeted for structural grouted connections in wind turbine foundations and concrete tower joints – says Niels Peter Andersen, Sales Manager – Onshore Foundations – Europe – The new versatile Ducorit® grout can be installed in multiple applications, both for the grouting of the connection between the steel tower flange, and in pre-cast concrete element towers in vertical and horizontal joints”.

The product series was introduced to the market in August this year and the first projects have already been completed successfully. The product Ducorit R1G was chosen for the undercasting of tower flanges on a project in Lithuania where 24 GE wind turbines were installed.

The grouting was done by the contractor Merko Ehitus Eesti and project manager Risto Sappinen, who says, „It is always good to cooperate with a company who is interested in the final result. Shortly after signing the contract a training session was conducted at the ITW Plant in Aalborg, Denmark. The training was really useful and within short time we received both theoretical and practical knowledge about the product Ducorit R1G, the grouting operation and the machinery. ITW Supervisor Peter Severin Jensen was present at the site in Lithuania when we started grouting and even though the 1st day of grouting had temperatures above 30 degrees the final grouting result was good and the test cubes showed a good compresive strenght“.

Furthermore, the product Ducorit R1G has also been used for the undercasting of tower flanges on a project in Germany where GES installed 6 Gamesa wind turbines close to Hamburg, and Ducorit A2G was used in the concrete tower assembly process – both vertical and horizontal joints – on a project of 10 onshore Acciona wind turbines in Poland installed by Acciona Energia.

The new product series is tested in compliance with the German DAfStb “production and use of cement-bound cast concrete and mortars, 2011” and the material can be installed at ambient temperatures from 2°C to 35°C without any additional temperature precautions.

The grouting operation is not the product alone – but the entire setup around the process – and ITW WindGroup provides training, onsite supervision and equipment rental which enable a quicker, safer and a more efficient installation process.

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Karina Højgaard
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