The wind turbine foundation is a massive structure made of monolithic reinforced concrete (round in plan view and with variable thickness), its construction includes several stages.
At the first stage, a pile foundation is created, including from 230 to 314 driven piles per foundation. The piles length in accordance with local engineering and geological conditions reaches 16 meters. The weight of one pile – 4 tons. The amount of concrete per one pile is 2 cubic meters.
Driven piles are reinforced concrete products manufactured in factory conditions, they are rods with a square cross section and one pointed end. Piles are driven into soil by the impact method, creating a reliable and stable base for the foundation with maximum bearing capacity. Special installations are used for driving piles – drivers equipped with hydraulic or diesel hammers.
Then the grillage is reinforced on that base using approximately 60 tons of rebars. About 30 people are involved during the reinforcement, while the work is performed 24 hours during one week. During reinforcement, anchor basket is installed, the first components of the wind turbine tower are subsequently mounted on it. About 25 items of machinery and about 50 people are used in the concreting process. This is a thorough and laborious process that requires attention and precision. The grillage of the wind turbine foundation contains about 570 cubic meters of concrete. This large amount of concrete serves as an anchor to support the wind turbine during its operation.
After the foundation concreting is completed, concrete curing begins, it takes approximately 5-10 days, during which the construction control laboratory and specialists carefully monitor the temperature mode to achieve the necessary foundation strength. It takes 28 days to achieve the required concrete/foundation strength. After gaining strength, the foundation is ground and waterproofing is applied.
Then backfilling is carried out with layer-by-layer compacting by rolling and filling of the site near the wind turbine foundation, in order to install high-capacity cranes for the installation of wind turbine. The underground part of the wind turbine foundation has a diameter of about 22 meters, which is not visible from the outside.
*Grillage is the upper part of the base, which usually connects piles or pillars. It is needed for the even distribution of loads on the base.
*Anchor basket is an anchor unit that is used to firmly attach the wind turbine tower to the foundation.