2019 TECHNICAL GRANT PROPOSAL

Limit to no more than 3 pages of writing plus resumes

Title: Novel Support Tower Concept for Wind and Concentrated Solar Power Projects
TYPE OF GRANT (select one):
Project Innovation Business Line Proof-of-Concept
Applicant Names
(Lead Applicant First) GBU / Function Email Phone
Sanj Malushte NS&E / Engineering smalusht@bechtel.com (703) 429-6798
Bernie Krantz Infrastructure / Engineering bjkrantz@bechtel.com (571) 262-5913
Jaspal Saini Infrastructure / Engineering jssaini@bechtel.com (571) 392-6543
Hongchun Liu Infrastructure / Engineering hliu1@bechtel.com (571) 392-3488
Bill Olson Infrastructure / Construction wpolson@bechtel.com (405) 593-9268
Sponsoring GBU MoE Name GBU Email Phone
Sujal Lagowala Infrastructure slagowal@bechtel.com (571) 392-6754

Brief Proposal Summary

Both wind power and concentrated solar power projects require tall towers to support the wind turbine and solar
receiver, respectively. Heights of around 400-ft or more are needed to support 5-MW plus wind turbines and
similarly tall towers are need for large solar thermal projects. The design and fabrication/construction of towers
becomes quite challenging for such heights, and the tower constitutes a significant part of the overall project cost
and schedule. As such, it is desirable for Bechtel to develop an efficient tower design/construction concept to
help distinguish us from the competition.
A good summary of current wind turbine support tower design options and their applicable height ranges can be
found at http://www.agirkonsult.com/wp-content/uploads/2011/02/10_48_report_high_towers.pdf. It is customary
to use tapering tubular towers made from thick rolled steel plates for wind turbines up to about 400-ft tower height;
however, this approach becomes uneconomical for taller towers as the plate thickness gets close to 3-inch at the
bottom (the plate thickness is driven by long-term fatigue and compressive stresses due to the design overturning
moment due to wind loading). Lattice steel towers are being considered for taller configurations; however, they
require many members and complicated welded joints. A presentation on concrete & other tower types used for
taller towers is found at https://kupce.ku.edu/sites/kupce.ku.edu/files/docs/cpep/structural/speaker-presentations-
2017/Wernli.pdf. Concrete towers require a larger cross-section & prestressing, which adds costs/complexity.
This proposal presents a novel tower concept based on the idea of Concrete-filled Double-Skin Tube (CFDST)
columns. CFDST columns typically involve a square or round tube centered inside another square/round tube,
with concrete placement between the two tubes. They have been shown to produce very strong columns that are
buckling-resistant and have so far been studied and used for relatively small sizes (see a related article at
https://steeltubeinstitute.org/hss/2016/02/17/hss-enews-october-2015-concrete-filled-double-skin-tubes/). This
study proposes extension of CFDST column concept for use as a tapering octagonal CFDST tower that will be
made of 40-60 feet tall tiers, each comprised of eight flat concrete-filled steel-plate composite (SC) panels. Each
SC panel, which will make up the eight sides of the octagon, will be up to 12-ft wide and up to 2-ft thick and with
up to 1-inch thick steel faceplates. The SC panel faceplates will be tied together with up to ¾-thick vertical web
/spacer plates spaced at 3-4 feet. A tapering tower profile will be used such that the flat-to-flat outer dimension of
the tower will be up to 29-ft at the base and up to 17-ft at the top, respectively. The steel plate thickness (and
possibly wall thickness) will likely be smaller for the upper tower portions. If needed (especially for the wind
turbine application), a central column made of about 3-ft diameter pipe filled with concrete (i.e., a 36-inch
concrete-filled tube/CFT) will be used. The central CFT column will be braced against the eight corners of the
outer octagonal CFDST tower at every 20-ft to 30-ft. It is envisioned that the center column will support a portion
of the nacelle and wind turbine rotor weight and could be useful for supporting crane operations during the
CFDST tower erection. Also, if necessary, in lieu of the radially oriented web plates at the eight corners of the
octagon, rectangular CFT columns or embedded wide flange steel columns could be used to facilitate the tower
erection/installation operations (e.g., for supporting a tower/gantry crane); the corner shapes will also increase the
tower’s strength and stability.
The modular SC panels that make up the octagonal tower will have simple geometry and will, therefore, be easy
to assemble/fabricate and transport on a 60-ft long trailer bed. Once at the site, subject to rigging capabilities and
the ability to perform site fabrication operations, they could be further assembled to form a single 60-ft tall tier of
the octagonal tower. Alternatively, each rigging operation could lift a single SC panel into its final position. Also,
subject to concrete placement capabilities, each panel (or the partial/entire 60-ft tall octagonal tier) could be filled
with concrete before or after its installation. The proposed tower concept is illustrated in Figure 1; Details 1 and 2
show two options for truckable modules (to reduce welding, bolted flanges could be used for the horizontal and/or
vertical field/shop connections between panels).
QUESTIONS:
1. Why is this innovation promising?
The CFDST tower will have higher strength and stiffness than a comparable concrete tower (and will not need
any prestressing). It will also be easier and faster to erect the CFDST tower. The tower footprint and, hence,
its foundation will be smaller than a concrete tower, making the tower foundation also more economical.
The CFDST tower also has advantages over a tubular steel tower (even for heights less than 400-ft). Shop /
field welding operations will involve simple weld geometries such that most (if not all) of the welding can be
automated. Also, the individual (and collective) plate thicknesses are smaller, and the plates will be straight.
This is because: (1) the faceplates will be prevented from buckling due to their anchoring into the concrete
infill, and (2) the cyclic stress range due to dynamic wind load will be smaller because there will be negligible
compression stress due to the composite action with concrete. Finally, owing to the smaller faceplate
thicknesses, the total weld volume will be smaller and accordingly the welding time/costs will be reduced.
2. With which market or work process application is the proposed grant concerned?
The CFDST tower is envisioned as the support tower for onshore and offshore wind power projects as well as
for solar thermal projects. For offshore wind power projects, a large concrete pad or other suitable transition
piece could be used to support the tower on top of a lattice jacket structure that is anchored to the seafloor.
3. How can the proposed grant contribute to Bechtel’s competitive advantage?
To be successful in the mature and extremely competitive onshore wind market, Bechtel must look for
opportunities to differentiate ourselves. This has been a key challenge to the wind team from Craig Albert.
As turbines get larger and associated hub heights increase, we can differentiate ourselves from the rest of the
market by offering a solution that includes the design, fabrication, and installation of support towers and their
foundations that are technically viable alternatives to traditional technologies, economical and quick to build.
The proposed concept enables this; also, nobody among our competitors has explored/attempted this idea.
4. How would the results of the proposed grant be institutionalized?
This study will explore the feasibility of CFDST tower design and will come up with a representative tower and
foundation design for up to 600-ft tower applications. As a next step, subsequent interaction/partnership with
wind/solar power vendors and steel fabricators/erectors will be necessary for eventual commercialization.

Proposed Schedule
Month 1: Obtain tower design parameters from vendors and develop the CFDST Tower Concept
Month 2: Finalize the CFDST Tower Concept, develop suggested rigging/installation schemes
Month 3: Discuss tower fabrication/erection concepts with Construction/Rigging/other stakeholders
Month 4: Perform preliminary tower design calculations, begin report writing
Month 5: Perform preliminary foundation design calculations, finalize rigging/installation schemes
Month 6: Develop cost estimates and finalize the report

Budget:
Technical Grant: US $20,000
Co-Funding **: US $20,000
Total: US $40,000
Percent Job-hour Cost 95%
Percent Travel: 5%
Percent Subcontract or Purchases: 0%
Total 100%
Infrastructure GBU
** Source of co-funding (where applicable):
(pending confirmation)
Name of GBU MoE recommending the technical grant: Sujal Lagowala
Signature of GBU MoE:
** Where applicable, the sponsor confirms the availability of co-funding
Rev: 26-Mar-2018
 See Detail 1

Web/Spacer
Plates (TYP) Corner Plates
(TYP)

Shear studs
(TYP)

Corner Plates Web Plates

(TYP) (TYP)

A A
Outer & Inner
Face Plates
Outer & Inner (TYP)
Face Plates
(TYP)
DETAIL 1
Representative Truckable Panel,
Option 1, Up to 60' Long
See Detail 2 NTS

Column Brace
Up to 12'-0"

(TYP)
Shear studs
(TYP)

PLAN AT BASE
Shear studs not shown for clarity.

CFT Column
Column Brace,

(Optional)
~ every 30'
(TYP)
NTS

A A
SECTION A-A
Corner plates, web plates, and studs
not shown for clarity.

45°
~7'-0 3/8" DETAIL 2
Representative Truckable Panel,
Option 2, Up to 60' Long
NTS
PLAN AT TOP

Figure 1: Plan and Section Views of CFDST Support Tower