Scon Infra is revolutionising windmill tower construction using prestress technology

In India, windmill towers (pylons and fans) were traditionally made of steel. However, with the advancement and availability of prestress technology, designers have started constructing windmill pylons using concrete. One such landmark project is the successful construction of a prestressed concrete windmill tower by Scon Infra Prestress LLP in Mulanur, Chennai.

Structural design

Scon was commissioned by Nordex to deliver 120-m high prestressed concrete towers. The turbine tower is composed of 10 modular segments, each made of precast prestressed concrete. High-density wires were inserted into internal ducts to prestress the concrete, significantly enhancing the structure’s strength. The full tower, reaching a height of 120 m, was constructed using this technique. 

Innovative testing and structural validation

Scon has tested their system for 2 million cycles, which is for earthquake analysis. These tests conducted under CTL Chicago standards validate the structure’s resilience to seismic forces, extreme wind loads, and other environmental pressure.

A future built on prestressed concrete

With prestress technology, the almost anything can be done in the planning stage itself, like helipad, swimming pools, building with gardens, etc. The use of prestressed concrete towers in wind energy projects like the Mulanur Windmill signals a paradigm shift towards renewable infrastructure. Scon envisages the use of more software & digitalisation of drawing will open a door for prestressed designed structures.

Why move away from steel and use prestressed concrete?

Steel is costly and consumes more in conventional RCC. Prestress steel is affordable and saves a lot of reinforcement quantity. Similarly, Fe 415 and Fe 550 are the steel reinforcement available. But, the available prestressed steel is 1400 MPa (1400 N/mm²). Because of this, prestressed concrete has almost three times more strength than reinforced concrete. Normally, in prestressed slabs, the reinforcement quantity is 1 to 1.5 kg/cm² for normal loading, which is 3.5 to 4 kg in conventional RCC. So there are good savings while using prestressed technology.

Prestressed concrete presents a technically and economically attractive alternative for modern wind turbine towers, especially those exceeding 70 m in height. Apart from this, prestressed concrete towers can handle loads better, can be made locally to save transport costs, last longer in coastal or harsh areas, use materials that are easier to find, allow for taller and slimmer designs, and need very little maintenance.

For more details, visit: https://www.sconinfrastructure.com/