Structural Technology Seminar - RI Precast Concrete Bridges and Wind Towers

MASTER IN STRUCTURAL AND CONSTRUCTION ENGINEERING
Structural Technology Seminars
RESEARCH AND INNOVATION IN PRECAST CONCRETE BRIDGES

AND TOWERS FOR HIGH POWER WIND GENERATORS
Antonio Marí
Professor of Civil Engineering
Dep of Civil and Environmental Engineering
High Performance Precast bridges and
towers for wind power generation
Table of contents
1. General prefabrication concepts

• What is prefabricating a structure?
• Prefabrication vs. on-site construction: Advantages and disadvantages
2. Precast concrete bridges

• Historical evolution
• Continuous precast concrete bridges: conceptual and practical aspects
• Theoretical and experimental studies
• Types of precast bridges with structural continuity
• Future perspectives: seismic zones, large spans
3. Precast concrete towers for wind power generators

• Basic concepts: power and structural types
• Concrete towers: alternative solutions
• SCS post-tensioned prefabricated tower.
• Concept, design and construction
• Theoretical and experimental studies 2
General Prefabrication Concepts
¿What is prefabricating a structure??
It is to fabricate a part or all the elements that form a structure in a place

different to the final site where they are going to be in service
It implies a production in a factory or on near the construction site, handling,

gathering , transportation placement on site and assembly of elements,
PREFABRICATION = INDUSTRIALIZATIÓN
“Aplication to construction industry production techniques in high

performance fixed installations, with high levels of quality control”
Light / Heavy Prefabrication: Function of dimensions and weight

Closed/Open Prefabrication : Function of the participation of the structural
designer in the elements design 3
Advantages of prefabrication
USE OF HIGH PERFORMANCE MATERIALS
High strength concrete
1) Allows dimensional control: reduction of thickness and weight

2) Increment of durability, impermeability, best finishes
3) Higher strength and stiffness
3.1) Shear strength
3.2) Bond anchorage
3.3) Less delayed losses
Self-compacting Concrete: Suitable for prefabrication, occupational health
Fiber reinforced concrete: Constructon in factory makes compacting easier
Recycled aggregate concrete: In factories, defective elements can be recycled

Limitations of prefabrication
• WEIGHT AND SIZE OF ELEMENTS: In heavy prefabrication, need for powerful

means of handling and elevation, transport difficulties, etc.
• LACK OF MONOLITHISM AND CONTINUITY: Need to solve it on site
• REDUCED THICKNESS : satisfaction of durability and fire resistace

requirements, low shear strength because crushing of compression struts
• LACK OF TRADITION IN DESIGNING STRUCTURES WITH PRECAST ELEMENTS:

Less availability of methodologies and design computer programs
• HISTORICAL HERITAGE : Prefabrication associated to statically determinate,

ugly, non valid for seismic zones, etc.
PRECAST STRUCTURES :
Bridges
Buildings
Stadiums, bleachers
Foundations, walls, panels
Wind towers, masts, airport control towers
Pipelines, culverts, underpasses
Precast concrete element, which is part of a network,

either of fluid collectors or as part of a cable joint
(as in the case of an electric chamber).
The main function of a camera is to allow access to

the network for inspection and / or maintenance.
Channels, aqueducts
Water tanks
Tunnel segments
Docks, floating structures
Elements for piers
Acoustic walls
Aesthetically decortive elements
Street/Urban forniture
High Performance Precast bridges and
towers for wind power generation
CONTINUOUS PRECAST CONCRETE BRIDGES
20
21
EVOLUTION OF PRECAST CONCRETE BRIDGES IN SPAIN
Developments on Precast Concrete Bridge Decks
22
EVOLUTION OF PRECAST CONCRETE BRIDGES IN SPAIN
Developments on Precast Concrete Bridge Decks
Evolution of cross-section for

increasing width
•Double box girder beams
•Single box beam with stiff top slab
•Multi-cell box beams
•Inclined transverse struts
•Transverse ribs
•Combinations of them
23
PREFABRICATION VS CAST-IN-PLACE IN BRIDGE CONSTRUCTION
A “classical” approach
Advantages of Prefabrication Advantages of “on site” construction
•Industrialized construction: tolerances, material •Monolithism, structural continuity and redundancy

quality, product homogeneity and durability,
•Usable in different structural types (continuous
•Cost. No scaffolding needed; parallel production beams, arches, portical frames…)
and construction
• Adequate solutions for seismic performance.
• Independence from on site sorroundings: weather
harshness , traffic or water floods. • Combination of materials: reinforced/prestressed
concrete and constructon methods (launching, etc)
• Fast and safe construction. Work-zone safety for
the public traveling and contractor personnel • Aesthetic appearence. Shape freedom
• Reduction environmental impacts, less materials • Accesibility to difficult sites provided by

and energy consumption, dismountability conveniently splicing precast segments
Disadvantages of prefabrication Disadvantages of “on site” construction

•Need for powerful tools of transport and handling •Execution conditions: climate, homogeneity, D
•Limitations of size and weigh for transport / access Difficulties o get high strength concrete
•Stiffness in shapes and structural types (simply sup) •Cost of scaffolding, traffic affection, risk of floods
Rigidez de formas y tipos estructurales •Construction: work in series (sequentially) 24
•Elements connections, non-continuous structures •Labour risks (more time of personnel on site)
THE NEW GENERATION OF PRECAST CONCRETE BRIDGES
• Combine advantages of precast and cast in place construction
• Constant or variable depth
• Straight or curved in plan
• Structural continuity by means

of post-tensioning
• Adaptable to any structural type
• Adequate for short, médium

and long spans
25
¿Why has been this evolution posible?
• Development of high performance concrete and steel, and use of post-tensioning

to connect precast elements and provide continuity and monolithism
• Possibility of transporting, handling and erection of large and heavy elements:

technological tools (cranes, trucks, roads) and legislation permission.
• Contract legislation which allows the contractors to offer a modified solution to

that existing in the original project, provided that the tecnical performance and
economical cost are satisfactory
• Capacity to perform large scale tests with, introducing large loads and measuring
with high precisión, using ICTechnologies
• Development of efficient and rigurous computational models capable to simulate

the experimentally observed structural behavior
• Cooperation between University, Public Administrations and Precast Companies in

research and innovation. 26
Main characteristics of a typical precast continuous bridges
Continuous box girder bridge decks with side cantilevers, composed by:
- Precast prestressed (pretensioned/post-tensioned) spliced U-girders
- Cast-in place reinforced and/or post-tensioned concrete top slab,

using free-standing planks as formwork.
Each U-girder has their own post-tensioning, totally finished at factory.
Free-standing planks :
Get a fast surface to work on it
Increase of safety on top slab task
At least 3 pouring stages for slab

Central slab at hogging areas
Central slab at sagging areas
Cantilevers
28
“U” or “bath” girder with end diaphragms and shear keys.
Continuity of the deck provided by longitudinal post-tensioning of the beams

crossing the end diaphragms and by the cast in place reinforced and/or
postensioned top slab
Observe the shear keys and the ducts

for long post-tensioning cables
to provide structural continuity 29
Phased construction of a typical overpass
30
Main characteristics of a typical
precast continuous bridges
Joint between beams.
Shear keys
Corbels
End diaphragms
Continuity by prestressing
STRUCTURAL BEHAVIOUR, THEORETICAL
AND EXPERIMENTAL RESEARCH
Characteristics of the phased construction process
•Changes in support conditions:

Use of temporary shores, pier-deck
monolithic connection if necessary
•Changes in links between precast

elements : longitudinal continuity
introduced by means of beams
post-tensioning and by top slab.
•Changes on structural scheme

and phased concreting of the slab
•Beam and slab concretes of Las Pilas bridge (Barbastro, Spain).

different class. Prestressed L=30+60+60+60+30m
and reinforced members First medium span continuous precast bridge with
spliced bath-tube girders in Spain 36
Structural effects of the phased construction process
0.50
Losa
0.00
• Changes of Internal forces,
Cota desde cara inferior viga (m)

stresses and strains along the
Puente Bogunya. Sobrecarga vanos extremos
-0.50 Tensiones en el hormigón. Vano 1
Peso vigas + pretensado
Largo plazo cargas permanentes
construction process,
Largo plazo sobrecarga
-1.00 Viga
•Possible cracking of slab due to -1.50
constrained shrinkage: stiffness -2.00
modification 0.00 -1000.00 -2000.00

Tensión en el hormigon (T/m2)
-3000.00
4500
4000
•Time-dependent redistribution of 3500
3000
stresses (between beam and slab, 2500
steel and concrete) and internal Momento Flector (T·m)

2000 Puente Bogunya.
Evolucion en el tiempo de Momentos Flectores
durante construcción y bajo cargas permanentes
1500 Momento en vano lateral
forces, due to creep, shrinkage and

Momento en apoyo
1000 Momento en vano central
500
relaxation 0
-500
-1000
-1500
-2000
-2500
-3000
10 100 1000 10000

Tiempo (días)
Design must take into account the construction sequence 37

Analytical model developed (CONS).
Non-linear and time dependent analysis of segmentally erected 3D concrete

frames. (UC Berkeley, UCB SESM Report 84-12, A. Marí and AC Scordelis)
 Filament beam finite elements
Non-linear σ - ε . Cracking, T. Stiffening, yielding, crushing, load reversals
 Step by step time-dependent analysis: Effects of creep, shrinkage, relaxation ,
time dependent evolution of concrete properties and segmental construction
 Structural response in the elastic, cracked and pre-failure states
Concrete y
Filamento de acero
Filament Reinforcing
(armadura pasiva) Steel
Filament
Steel Plate
x Filament
38
Simulation capacities of the model
• Any construction process: cantilever, incremental launching, precast.
• Effects of materials deterioration on the structural response (corrosion, etc)
• Repair, strengthening and retrofit of damaged or undamaged structures
• Remodelling, widening or demolition of existing structures
39
Example of the analysis results.
Bridge over the Gállego River in Zaragoza
Viga 1 Viga 2 Viga 3 Semiviga 4
E-7 E-12 E-20

6 21 36 56 68
4 5
Estribo 1 Pila 1 E-1 E-68
2 3
1
0 10 20 30 40 50 60 70 80 90 100 110 120
-6000
-5000
-4000
Momento Flector (t·m)
-3000
Puente Rio Gallego Zaragoza
-2000 Evolucion momentos flectores en
construccion y bajo c. permanentes
-1000 aplicadas a los 120 dias referidos a
centro de referencia de la seccion
0 Momento sobre pila V en viga 3
Momento en el centro del puente
1000
2000
3000
4000
10.00 100.00 1000.00 10000.00
Log t (dias)
Evolution of bending moments law during construction
and under permanent loads
-6000
-5000
Puente Rio Gallego - Zaragoza
Momentos Flectores en el tablero
-4000 Ref. al cd referencia en union viga-losa
En vigas con axil hay que descontar N·e
Tras eliminar torretas t=72 dias
-3000
Bajo cargas permanentes t=120 dias
Momento flector (t·m)
Bajo carga permanentes a largo plazo

-2000
Justo antes de eliminar torretas
-1000
1000
2000
3000
4000
0 10 20 30 40 50 60 70 80 90 100 110 120

Distancia al estribo (m)
Bending moments (T.m) Over V support Center span
End of construction -5860 2489
At 10.000 days -4648 3722
Redistribution (%) -20,7% 49,5%

0.080
0.070
Flechas en vanos 1 y 2
0.060
Centro vano 1- Nodo 12
Desplazamiento (m)
0.050 Centro vano 2 - Nodo 19
0.040
Union pila en V- Nodo 36
Evolution of
0.030 deflections,
0.020
0.010
deformed shape
0.000 and stresses
-0.010
10.00 100.00 1000.00 10000.00
Log t (dias) 0.4
0.2
0.14
0.0
0.12 Deformada en construccion
Distancia a fibra superior viga (m)

-0.2
y bajo CP a largo plazo Puente Rio Galligo - Zaragoza
-0.4 Tensiones Seccion Centro Vano 1
0.10 Antes de retirar torretas Tensiones iniciales viga P.propio + pret
-0.6 Tras aplicar carga muerta t=120 dias

Despues de retirar torretas A largo plazo en viga y en 2 fases losa
0.08
Desplazamiento (m)
Aplicacion carga permanente -0.8
Bajo CP a largo plazo -1.0

0.06
-1.2
0.04
-1.4
0.02 -1.6
-1.8
0.00
-2.0
-0.02 500 0 -500 -1000 -1500 -2000 -2500

Tensiones (T/m2). Compresion negativas
-0.04
-0.06
0 20 40 60 80 100 120
INTRODUCCIÓN
Experimental investigation.
GENERAL OBJECTIVE
• To study the structural response and flexural strength during

construction, under permanent loads and under increasing load
up to failure.
• Obtain reliable information and experimental evidence of the

structural behaviour, in special, the joints performance
• Calibrate numerical tools developed
• Sensitivity study of most relevant parameters governing the

structural behavior
• Provide design recommendations.

44
DESCRIPCIÓN DEL MODELO EXPERIMENTAL (2/3)
1/2 SCALE EXPERIMENTAL MODEL
45
DIMENSIONS OF EXPERIMENTAL MODEL
RC beam Post-tensioned joint PC beam
Cast in place slab
Precast beam
46
SEQUENTIAL CONSTRUCTION PROCESS
R.C. Beam
P.C. Beam
Placement of sand
Top slab over the R.C.B.
Top slab over the join
Top slab over the P.C.B.
Deal load (hollow core

slabs)
47
NUMERICAL SIMULATION AND COMPARISON WITH EXPERIMENTAL RESULTS.
Strains at the center of prestressed beam during construction
Top Reinforcement
-2000
-5 %
-1600
Strain [µm/m]
-1200
-800
-400 Numerical Results

Mean Experimental Values
0 10 20 30 40 50 60 70 80 90 48
Time (t-tp) [Days]
ENSAYOS SOBRE LA ESTRUCTURA
Permanent loads and unloading
49
50
45
40 Numerical
35
30 Experimental
25
Deflection (mm)
20
15
10
5
0
-5
-10
-15 5%
-20
-25
-30
0 100 200 300 400 500 600 700 800
Time (days) 50
-1500
Tras la colocación de la carga muerta
-1000 -1007 Previo a la descarga t-tp=573 días

-880
Posterior a la descarga
-638
-500 -568 Final t-tp=649 días
Momento [kNm]
500
5% 997
1000
1136
1197
1500
0 2 4 6 8 10 12 14 16 18 20 22 24
X [m] 51
-2000
-1600
Micro-strains
-1200
-800
Bottom reinforcement. Numerical
Top reinforcement. Numerical
5%
Bottom reinforcement. Experimental
-400
Top reinforcement. Experimental
0
0 100 200 300 400 500 600 700 800
Time (days) 52
Resultados experimentales y comparación con predicciones
1400 50
45
1200 EXPERIMENTAL NUMERIC
40 Numerical
Total load 35
1000
Support 2
30 Experimental
Support 3
25
Deflection (mm)
Support 1
20
Load [kN]
800 15
10
600 5
0
400 -5
-10
-15
200 -20
-25
0 -30
0 100 200 300 400 500 600 700 800
0 100 200 300 400 500 600 700
Time (t-tp) [Days] Time (days)
-1500
Tras la colocación de la carga muerta
-1000 Previo a la descarga t-tp=573 días

-2000
-1007
-880
Posterior a la descarga
-638
-500 -568 Final t-tp=649 días -1600
Momento [kNm]
5%
Micro-strains
0 -1200
500 -800
Bottom reinforcement. Numerical
Top reinforcement. Numerical
997 Bottom reinforcement. Experimental
1000 -400
1136 Top reinforcement. Experimental
1197
1500 0
53
0 2 4 6 8 10 12 14 16 18 20 22 24 0 100 200 300 400 500 600 700 800
X [m] Time (days)
CONCLUSIONS OF THE RESEARCH WORK
- Satisfactory behaviour according to experimental results
- Excellent performance of post-tensioned joints. No opening at all .
- Delayed deformations higher than (specially shrinkage)

-
- Low level of forces redistributions along the time
- Cracking of slab due to constrained shrinkage. Reduction of stiffness contribution
- Good prediction of structural response by the numerical model
- Large influence of construction process on final state of stresses/strains, cracks

and deflections.
54
SR designed and constructed precast continuous bridges i Spain
Straight, constant depth continuous deck
55
Straight, variable depth continuous deck
56
Curved in plan, constant depth continuous deck
ALSASUA E-8 (1997) 57

(Main span 125ft/38m)
Precast concrete curved bridge over the High speed train in Guipuzcua
Radio = 50 m. Constructed in 3 nights. Fully precast, included the piers58

Straight in plan, constant depth widened with laterat struts
59
Curved in plan, constant depth widened with laterat struts
60
Straight, constant depth with longitudinal struts for medium – high spans
61
Straight, constant depth extra-wide deck with longitudinal struts for medium – high spans
P L VS VLTRA
67
68
69
Straight, constant depth portical bridge Upper deck arch bridge
70
Pedestrian Arch Bridge in Bilbao
Design and construction solutions

for complex geometries:
-“Fork” type decks (bifurcations)

- Decks with a great variable width
If required, monolithic connection to piers.
73
RESEARCH AND DEVELOPMENT NEEDS
Research needs
Use of partial prestressing to optimize the design, minimizing the global cost
Accounting for concrete, mild and prestressing reinforcements
Use of Steel Fiber Reinforced Concrete (SFRC) to reduce the amount of shear
reinforcement and the dimensions and weight of the precast elements.
Design and experimental verification of earthquake resistant precast concrete bridges
Optimal design of precast concrete bridges (span lengths, type and number
of beams, ec) taking into account the whole process: fabrication, transport,
erection, materials and energy consumtion
Theoretical and experimental studies on the combined shear, torsion and

bending strength of decks comp’osed by precast prestressed beams + cast in
place reinforced concrete slab
Study of the optimal construction sequence of precast continuous concrete decks

and evluation of short and long-term forces and stresses redistributions
Explore the economical feseability of using external prestressing in this estructural type
RESEARCH AND DEVELOPMENT NEEDS
Development needs
Computer programs for the optimal flexural design of precast concrete sections
for pre-tensioned, post-tensioned and partial prestressing designs, including the effects
of short and long-term prestressing losses. They may need a non-linear analysis if
cracking is allowed, but can be excel sheets based programs
Simplified computer programs for the longitudinal beam-model analysis and design of
precast beams+ RC slabs, accounting for construction phases, secondary prestressing
effects, continuity force and internal short and long-term forces redistribution.
Computer programs for shear/torsional design of precast concrete beams + slabs,

As well as for the design of shear reinforcement in the joint beam/slab
Solutions for the detailing of anchorage zones, both in pre-tensioned strands and in
post-tensioned tendons, as well as support zones, diaphragms and D regions using
strut and tie models and if possible, experimentally verified.
Development of adequate solutions for handling, storage, transport and assembly
Others...
RESEARCH AND INNOVATION IN PRECAST TOWERS FOR HIGH POWER WIND GENERATORS
PRECAST PRESTRESSED CONCRETE

TOWERS FOR HIGH POWER WIND
GENERATORS
Power and wind energy
A
• Power developed by the turbinea.
1
P = ρ ·A ·v 3 · C p
2 v
P = Power
ρ= air density(1,225 Kg/m3)
A = Area covered by the rotor
V= wind speed
Cp=Power coefficient.Fraction of wind power
that can be converted in mechanical work
Cp≤0,593 (Bents limit)
• Energy = Power· Time

Evolution of wind towers
-Typical power usually 0,9 -2 MW, H ≤ 80 m

-Wind farms placed on sites with high winds, as mountain summits,
very occupied
Evolution of wind towers
-Need to increase the power to be placed on less favourable sites
- Plain zones, but higher towers: higher wind speed

- Increase of blades length (W = f(S)) and tower height
- Increase of forces, base diameter and wall thickness
Limitations of steel wind towers
- Current steel solution, Base diameter Db<4,30 m

- Trunk conical segments
- Only Horizontal joints
- Easy transport and handling
When Db > 4,30 m

-Problems to road transport in segmentos trunk
conical segments due to height and width limitations
-Need for vertical joints
-Considerable steel plates thickness
-Difficulties of assembling and joint execution on site
(welding, etc)
In these conditions, the structural Concrete

becomes a competitive material
Concrete wind towers
¿Reinforced?, ¿Prestressed?, ¿Cast in place?, ¿Precast?
-Aspects to be considered
-Analysis and design

- Crack control (Durability)
- Dynamic response (Stiffness, damping)
- Strength of shell, edge beams and joimts
- Fatigue problems
-Execution
- Materials to be used
- Execution time
- Accessibility on site (transport)
- Manufacturing/transport/handling and assembling
easiness
- Cranes, formwork and auxiliary means
- Labour safety along the whole process
- Energy comsuption/environmental impact of works
- Service life, maintenance and repair
- Dismounting/demolition/re-using
Concept of the developed precast concrete tower
Made in Cooperation with GAMESA and NORTEN

Three R+D prototypes constructed in Spain
Modular tower of prestressed concrete + upper part

made on steel.
Precast. Thin Shell with vertical and horizontal ribbs

where post-tensioned cables are embedded
Adaptable to any power and dimensions
Connected to foundation by prestressed bars
120 m height (84 concrete +36 Steel)

Precast post-tensioned tower elements
Posible modulations Precast Element Inside view of the tower

Ribbed thin shell
Precast post-tensioned tower dimensions
Total height 120 m: 82 m concrete + 38 m Steel
Wind turbine power: 4,5 MW
Blades length: 60 m
Base/top diameters : 8,50m / 2,50m
Number of segment: 4 (23m+19m+20m+20 m)
Number of pieces : 20 (6+6+4+4)
Shell thickness: 0,14+0,13+0,13+0,14 m
Number of vertical ribbs: 12 along the whole height
Number of horizontal ribbs: 5 at each segment

Precast prestressed concrete towers
Precast post-tensioned elements (tiles)
Precast prestressed elements transportation
Precast prestressed concrete towers
Assembly of elements
Tile type elements are assembled to form trunk of cones
Special analytical and experimental studies
Special analytical and experimental studies
- Discontinuity regions
- Connection to foundation
- Possible hybrid towers : concrete +

steel pars connected
- Prototype monitoring and validation

Experimental Validation of the tower design
Instrumentation Objetives
• Validate 118 m (82 m concrete) hybrid tower
response against project actions.
•Check proper behavior together (horizontal and

vertical). Validate door zone response (region
Tipo de sensor
Strain gauges in reinforcement Transverse sections and door zone
Strain gauges in concrete Door zone
Potenciómetreters Joints
Thermo pairs Environmentsl snf angular

distribution in height
Load Cells Anchorage bars
Metodology
•Continuous register and verification of under reproducibles
design situations:
-Production for different wind speeds
- Machi ne at slow motion
- Emergency stop
- Network failure
- Activaction of the high speed protection system
• Tolerances: Recommended Monography M-9 ACHE

Results
Comparison theoretical and measured strains at Moment- strains at different reinforcing bars of a
two sensors placed in the door zone cross section
1: Emergency Shutdown_eds1 y eds3 Mod1 Bottom

1.5E-04 250
1.0E-04 200
150
5.0E-05
100
Observed strain
0.0E+00 50
0
-5.0E-05
-50
-1.0E-04 -100
-1.5E-04 -150
-200
-2.0E-04
-250
-1.0E-04 -8.0E-05 -6.0E-05 -4.0E-05 -2.0E-05 0.0E+00 2.0E-05 4.0E-05
-200 -150 -100 -50 0 50 100 150 200
Estimated strain
angle=114 angle=24 angle=294 angle=200
eds1 eds3 15% 60 micro -60 micro -40% "+60 me "-60 me "+15% "-15%
Situation: Emergency stop Situation: Activaction of the high speed

(Admissible tolerances range indicated) protection system
(Admissible tolerances range indicated)
Results
Shear stress – slip in vertical joint (mm) Shear stress – slip in vertical joint (mm)
12: Prod. Mz 12 m/s 12: Prod. Mz 12 m/s
Mod 4 Mod 4
0.30 0.30
0.20 0.20
0.10 0.10
τ*
τ*
0.00 0.00
-0.10 -0.10
-0.20 -0.20
-0.30 -0.30
-0.40 -0.40
-4.0E-03 -3.0E-03 -2.0E-03 -1.0E-03 0.0E+00 1.0E-03 2.0E-03 3.0E-03 4.0E-03 -4.E-03 -3.E-03 -2.E-03 -1.E-03 0.E+00 1.E-03 2.E-03 3.E-03 4.E-03
o s
Joint 45º Joint 315º Joint 45º Joint 315º
Conclusions of the study
- The measured experimental behavior responds to the expected elastic

behavior according to project calculations and established tolerances.
- There has been no relative movement in the instrumented joint

CONCLUSIONS
Concrete tower
-Tecnically and economically competitive in front of steel solution
-Adequate for mid and tall towers/hybrid
-Less maintenance
Prestressed Concrete
-Better crack control (specially when bonded prestressing)
-Higher durability
-Less amount of materials
-Higher strength (Moment, Shear, Torsion)
-Better dynamic response
Precast Tower
- Higher construction speed
- Less amount of materials
- Lower number of operations and labour risks on site
- Better finishes and higher concrete strength (>50 Mpa)
- Adequate solution both for inland and off-shore winf farms
- Need to adequately solve transport, assembly and joints
CURRENT TRENDS
- More powerful generators (6 MW)
- Taller towers (140-160 m)
- Shorter segments (less weight)
- Trunk of cone assembled on top
- Smaller cranes, which climb as the tower goes up.
- External post-tensioning (decommisionning)
- Less massive foundations (cross legs in spite of big footings)

RESEARCH AND INNOVATION IN PRECAST CONCRETE BRIDGES
AND TOWERS FOR HIGH POWER WIND GENERATORS
Thank you for your attention
Antonio Marí, Jesús M. Bairán (UPC)

Jesús Montaner, Fernando Osán, (SR)

Structural Technology Seminar - RI Precast Concrete Bridges and Wind Towers

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MASTER IN STRUCTURAL AND CONSTRUCTION ENGINEERING

Structural Technology Seminars

RESEARCH AND INNOVATION IN PRECAST CONCRETE BRIDGES

1. General prefabrication concepts

2. Precast concrete bridges

3. Precast concrete towers for wind power generators

¿What is prefabricating a structure??

It is to fabricate a part or all the elements that form a structure in a place

It implies a production in a factory or on near the construction site, handling,

“Aplication to construction industry production techniques in high

Light / Heavy Prefabrication: Function of dimensions and weight

High strength concrete

1) Allows dimensional control: reduction of thickness and weight

Self-compacting Concrete: Suitable for prefabrication, occupational health

Fiber reinforced concrete: Constructon in factory makes compacting easier

Recycled aggregate concrete: In factories, defective elements can be recycled

• WEIGHT AND SIZE OF ELEMENTS: In heavy prefabrication, need for powerful

• LACK OF MONOLITHISM AND CONTINUITY: Need to solve it on site

• REDUCED THICKNESS : satisfaction of durability and fire resistace

• LACK OF TRADITION IN DESIGNING STRUCTURES WITH PRECAST ELEMENTS:

• HISTORICAL HERITAGE : Prefabrication associated to statically determinate,

Precast concrete element, which is part of a network,

The main function of a camera is to allow access to

CONTINUOUS PRECAST CONCRETE BRIDGES

Evolution of cross-section for

Advantages of Prefabrication Advantages of “on site” construction

•Industrialized construction: tolerances, material •Monolithism, structural continuity and redundancy

• Reduction environmental impacts, less materials • Accesibility to difficult sites provided by

Disadvantages of prefabrication Disadvantages of “on site” construction

• Combine advantages of precast and cast in place construction

• Constant or variable depth

• Straight or curved in plan

• Structural continuity by means

• Adaptable to any structural type

• Adequate for short, médium

• Development of high performance concrete and steel, and use of post-tensioning

• Possibility of transporting, handling and erection of large and heavy elements:

• Contract legislation which allows the contractors to offer a modified solution to

• Development of efficient and rigurous computational models capable to simulate

• Cooperation between University, Public Administrations and Precast Companies in

- Precast prestressed (pretensioned/post-tensioned) spliced U-girders

- Cast-in place reinforced and/or post-tensioned concrete top slab,

Each U-girder has their own post-tensioning, totally finished at factory.

At least 3 pouring stages for slab

“U” or “bath” girder with end diaphragms and shear keys.

Continuity of the deck provided by longitudinal post-tensioning of the beams

Observe the shear keys and the ducts

Joint between beams.

Characteristics of the phased construction process

•Changes in support conditions:

•Changes in links between precast

•Changes on structural scheme

•Beam and slab concretes of Las Pilas bridge (Barbastro, Spain).

• Changes of Internal forces,

Cota desde cara inferior viga (m)

•Possible cracking of slab due to -1.50

constrained shrinkage: stiffness -2.00

modification 0.00 -1000.00 -2000.00

•Time-dependent redistribution of 3500

stresses (between beam and slab, 2500

steel and concrete) and internal Momento Flector (T·m)

forces, due to creep, shrinkage and

10 100 1000 10000