Method for fabrication of structures used in construction of tower base supports

Abstract

Disclosed are apparatus and corresponding methodologies for providing a base support, such as including concrete, and used such as for a wind-driven generator. Precast concrete cylinders are stacked in place upon a platform that may be partially precast and partially cast in place during assembly and supported, in certain embodiments, by plural concrete legs, the other ends of which are supported on a unitary or subdivided concrete foundation. In other embodiments, the platform may be supported by ribbed concrete panels. The concrete cylinders are glued together using an epoxy and then secured by an internal vertical post tension system extending from the platform to the upper most cylinder. Methodologies and apparatus for fabrication of concrete structure used in constructing the base support are also disclosed, with a focus on staves and various ring piece constructions.

What is claimed is: 
     
         1 . A method of fabricating structures for use in construction of a support tower, the method comprising:
 providing respective outer diameter and inner diameter forms with the outer diameter form situated adjacent to the inner diameter form so as to collectively provide a concrete form defining a casting volume, the concrete form having at least one inlet for injection of concrete into the casting volume and at least one outlet for the displacement of air therefrom;   injecting concrete into the casting volume;   curing the concrete in the casting volume so as to form a casting;   generating a first thermal gradient between the casting and the outer diameter form;   removing the outer diameter form from the casting;   generating a second thermal gradient between the casting and the inner diameter form; and   removing the casting from the inner diameter form.   
     
     
         2 . The method of  claim 1 , wherein the generating the first thermal gradient includes spraying steam onto the outer diameter form, or using at least one heater embedded in the outer diameter form, or combinations thereof. 
     
     
         3 . The method of  claim 1 , wherein the generating a second thermal gradient includes spraying water, air, or combinations thereof at ambient temperature onto the inner diameter form. 
     
     
         4 . The method of  claim 1 , wherein the removing the outer diameter form includes lifting the outer diameter form. 
     
     
         5 . The method of  claim 1 , wherein the removing the casting from the inner diameter form includes pushing up on the casting, or lifting the casting, or combinations thereof. 
     
     
         6 . A method of fabricating a concrete casting comprising:
 providing a first form and a second form with the first form situated adjacent to the second form so as to collectively provide a concrete form defining a casting volume, the concrete form having at least one inlet for injection of concrete into the casting volume and at least one outlet for the displacement of air therefrom;   injecting concrete into the casting volume;   curing the concrete in the casting volume so as to form the concrete casting;   generating a first thermal gradient between the concrete casting and the first form;   removing the first form from the concrete casting;   generating a second thermal gradient between the concrete casting and the second form; and   removing the concrete casting from the second form.   
     
     
         7 . The method of  claim 6 , wherein the first form and the second form both have a curved shape. 
     
     
         8 . The method of  claim 7 , wherein a radius of curvature of the first form and a radius of curvature of the second form are different. 
     
     
         9 . The method of  claim 6 , wherein the generating the first thermal gradient includes spraying steam onto the first form, or using at least one heater embedded in the first form, or combinations thereof. 
     
     
         10 . The method of  claim 6 , wherein the generating a second thermal gradient includes spraying water, air, or combinations thereof at ambient temperature onto the second form. 
     
     
         11 . The method of  claim 6 , wherein the removing the first form includes lifting the first form. 
     
     
         12 . The method of  claim 6 , wherein the removing the concrete casting from the second form includes pushing up on the concrete casting, or lifting the concrete casting, or combinations thereof.