Method for Vertically Extruding a Concrete Element, Device for Producing a Concrete Element, and Wind Turbine Generator Tower Produced by This Method

Abstract

Device for producing an elongated concrete element extending in the vertical direction, for example a tower of a wind turbine generator system, comprising an inner casing and an outer casing, the inner casing and the outer casing being configured in such a way that between the inner casing and the outer casing there is an interspace, which is of a height that is less than the height of the concrete element to be produced. A number of pumps are used, in order to pump concrete into the interspace. The pumps are designed in such a way that the concrete can be introduced at high pressure in such a way that the interspace is filled with concrete and that the concrete element is forced vertically upwards out of the interspace during the hardening of the concrete. As the concrete element rises, an attachments, that later serves for pulling up and mounting various elements, is transported upwards.

1 . Method for vertically extruding an elongated, itself in a vertical direction extending, cylinder shaped concrete element ( 20 ), with the following steps:
 providing an inner casing ( 12 ),   providing an outer casing ( 11 ), wherein between the inner casing ( 12 ) and the outer casing ( 11 ) an interspace ( 16 ) is formed, which has a height (H), that is less than the height (H 1 ) of the concrete element ( 20 ) to be finished,   introducing the concrete ( 21 ) in a lower area of the interspace ( 16 ), wherein the concrete ( 21 ) is inserted with high pressure so that the interspace ( 16 ) is filled with concrete ( 21 ) and that during the hardening of the concrete ( 21 ), the concrete element ( 20 ) is being extruded vertically upwards out of the interspace ( 16 )   
     characterized in that the concrete ( 21 ) is introduced in more than one place in the lower part of the interspace ( 16 ) and that on the concrete element ( 20 ) in an upper part an attachment ( 24 ) is placed, which is being raised upwards by the pushing out of the interspace ( 16 ) of the concrete element ( 20 ). 
   
   
       2 . The method according to  claim 1 , characterized in that during the introduction or before the introduction, the concrete ( 21 ) is provided with enforcement elements, wherein preferably synthetic, glass-steel, or carbon fiber are used as enforcement elements. 
   
   
       3 . The method according to  claim 1 , characterized in that the concrete element ( 20 ) is produced seamlessly from the concrete ( 21 ) and its height (H 1 ) increases as long as concrete ( 21 ) is introduced in the lower part of the interspace ( 16 ). 
   
   
       4 . The method according to  claim 1 , characterized in that internally or externally running tensioning means ( 25 ,  28 ) are fitted on the attachment ( 24 ), wherein a preferably triangular arrangement of tensioning cords ( 25 ) acts as tensioning means. 
   
   
       5 . The method according to  claim 4 , characterized in that, during the extrusion out of the interspace ( 16 ), the vertical alignment of the concrete element ( 20 ) is controlled through controlled tensioning of the tensioning means ( 25 ,  28 ). 
   
   
       6 . The method according to  claim 1 , characterized in that the means ( 28 ,  31 ) are fitted on the attachment ( 24 ), so that, after achieving the height (H 1 ) of the concrete element ( 20 ) to be produced, construction parts can be pulled upwards. 
   
   
       7 . The method according to  claim 1 , characterized in that, means are fitted on the attachment ( 24 ) so that construction parts can be fitted. 
   
   
       8 . The method according to  claim 1 , characterized in that the introduction of concrete ( 21 ) is controlled so that the concrete element ( 20 ) rises vertically. 
   
   
       9 . The method according to  claim 1 , characterized in that the inner and/or outer casing ( 11 ,  12 ) is made so that the cross section of the rising concrete element ( 20 ) can be changed. 
   
   
       10 . The method according to  claim 1 , characterized in that, in a preparing step, a foundation of concrete is provided, which is either arranged so that the inner casing ( 12 ) and the outer casing ( 11 ) can be fixed on this foundation, or arranged so that an integral part of the foundation acts as inner casing ( 12 ) and only the outer casing ( 11 ) must be fixed on this foundation. 
   
   
       11 . The method according to  claim 4 , characterized in that an electro-optical measuring device is used during the vertical extrusion, so that a deviation form the vertical direction can be detected, and thus, during the vertical extrusion, by means of the tensioning means ( 25 ,  28 ) a corresponding correction is conducted. 
   
   
       12 . The method according to  claim 1 , characterized in that during or after the vertical extrusion:
 outside on the cylindrical concrete element ( 20 ) a temporary shell, preferably a tubular shell is fitted, and/or   inside in the cylindrical concrete element ( 20 ) a temporary shell, preferably a tubular shell is fitted,   
     so that suitable environmental conditions are provided for the hardening of the concrete. 
   
   
       13 . The method according to  claim 4 , characterized in that the temporary shell(s) will be pulled from the ground during the extrusion. 
   
   
       14 . Device for producing on location of an elongated, itself in a vertical direction extending concrete element ( 20 ), with
 with an inner casing ( 12 ),   an outer casing ( 12 ),   
     wherein the inner casing ( 12 ) and the outer casing ( 11 ) are made so that between the inner casing ( 12 ) and the outer casing ( 11 ) there is an interspace ( 16 ), which has a height (H), that is less than the height (H 1 ) of the concrete element ( 20 ) to be finished, characterized in that several pumps ( 17 ) are provided for the introduction of the concrete ( 21 ) in more than one place in lower areas of the interspace ( 16 ), the pumps ( 17 ) are placed so that the concrete ( 21 ) can be introduced with high pressure in such a way that the interspace ( 16 ) is filled with concrete ( 21 ) and that, during the hardening of the concrete ( 21 ), the concrete element ( 20 ) is extruded out of the interspace ( 16 ) vertically upwards, and that on the concrete element ( 20 ), in an upper area, an attachment ( 24 ) is fitted, which is being raised upwards by the pushing out of the interspace ( 16 ) of the concrete element ( 20 ). 
   
   
       15 . The device according to  claim 14 , characterized in that means ( 15 ,  17 ,  18 ) are provided, so that the concrete ( 21 ) can be introduced in more than one place in the bottom part of the interspace ( 16 ), wherein preferably a centering means is used, so that the pressure in the bottom part of the interspace ( 16 ) can be controlled, that rises the concrete element ( 20 ) vertically. 
   
   
       16 . The device according to  claim 14 , characterized in that means are provided so that during the introduction or before the introduction, the concrete ( 21 ) can be provided with enforcement elements, wherein preferably synthetic, glass-steel, or carbon fiber are used as enforcement elements. 
   
   
       17 . The device according to  claim 16 , characterized in that the means ( 34 ,  35 ) are placed so, that iron bars or wire ( 32 ) as Monier-steel is inserted from below in the interspace ( 16 ) and will be shifted upwards with the concrete element ( 20 ). 
   
   
       18 . The device according to  claim 14 , characterized in that the inner casing ( 12 ) and the outer casing ( 11 ) are made so that they can be connected with a foundation ( 13 ,  14 ) on which the concrete element ( 20 ) is to be produced, whereby the inner casing ( 12 ) and the outer casing ( 11 ) are tightly connected to the foundation ( 13 ,  14 ). 
   
   
       19 . The device according to  claim 14 , characterized in that it comprises a concrete foundation, which features a cylindrical concrete wall, which acts as inner casing, and that the outer casing ( 11 ) is made so that it is connected with the concrete foundation, wherein the outer casing ( 12 ) is connected tightly with the foundation. 
   
   
       20 . The device according to  claim 14 , characterized in that the device comprises a control ( 40 ) and tensioning means ( 25 ,  28 ) are provided on the attachment ( 24 ), wherein, during the extrusion out of the interspace ( 16 ), through controlled tensioning of the tensioning means ( 25 ,  28 ), the vertical alignment of the concrete element ( 20 ) can be controlled by means of the control ( 40 ), wherein tensioning means ( 25 ,  28 ) relate to inner and/or outer tension cords. 
   
   
       21 . The device according to  claim 14 , characterized in that the device comprises a temporary inner and/or outer shell, preferably a tubular shell. 
   
   
       22 . Wind turbine generator tower with an elongated, itself in a vertical direction extending, concrete element ( 20 ), is extruded vertically in a continuous extrusion process from between an inner and an outer casing ( 11 ,  12 ), wherein the concrete element comprises an attachment ( 24 ), which during the extrusion process acts for the tensioning of the concrete element ( 20 ) and after the hardening of the concrete element ( 20 ) is suitable as lifting means ( 31 , 33 ,  36 ) for construction elements ( 50 ) of the wind generating turbine, which are to be fixed on or to the concrete element ( 20 ). 
   
   
       23 . Wind turbine generator tower according to  claim 22 , characterized in that it has a homogeneous composition through recrystallizing of clinker components of the cement used as part of the concrete ( 21 ). 
   
   
       24 . Wind turbine generator tower according to  claim 22 , characterized in that construction parts ( 50 ) of the wind turbine generator, like a gondola, a generator, or wind sails for example, can be lifted to the upper end of the concrete element ( 20 ) with the lifting means ( 31 ,  33 ,  36 ).