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PROBLEM? – SOLVED!


OFFSHORE WIND HIGH STRENGTH GROUTING TIMES INNOVATION


The teams at FoundOcean always believe there is room for improvement, with strategic material partners they are continually developing new materials and mixing technologies to help deliver lower cost and safer offshore projects.


MINIMISING COST


Minimising cost is high on the agenda for companies across all industries, up and down the supply chain. Many studies have been carried out into how to reduce CAPEX and OPEX costs associated with offshore projects, especially in offshore wind as governments strive to reach their 2020 low carbon goals.


GROUTING SPECIALIST FoundOcean is an offshore grouting specialist whose involvement is during the foundation installation phase. The grout is an essential component which contributes to the long-term structural integrity of the foundation turbine system, therefore its long-term capacity to generate revenue.


EXPERIENCES


Having worked on numerous offshore wind farm projects they discovered that grout mixing and pumping times were two areas where installation schedules could be reduced.


To overcome this, the company designed and built its new ‘Super Pan’ grout mixer enabling ultra-high strength (UHS) grouting to be completed in half the time of any conventional mixer.


This mixer, which was designed and built in-house, is designed to bring the mixing rates of UHS grouts nearer to that of standard strength grouts, which are normally around 4 times faster due to the different mixing process.


SPECIFICATIONS


Standard-strength grout projects make use of a high-speed Jet Mixer which is fed with cement from bulk storage silos. However the formulation of UHS grout is different to that of standard-strength grout, as a result silos cannot be used to store and transport the material as there is a risk of separation of key components within the material leading to inconsistency in the final material.


The Super Pan mixer achieves higher delivery rates by allowing larger volumes of grout to be produced by mixing larger batches, which in turn can reduce the number of crane movements used to carry bulk bags to the top of the mixer. It is the first mixer on the market with an UHS grout output rate exceeding 10m³ per hour.


WEST OF DUDDON SANDS Two Super Pan mixers were mobilised to the West of Duddon Sands Offshore Windfarm project. The company was saving 2 hours grouting time per foundation when compared to any conventional mixer.


For a project which requires 100 or more foundations, that amounts to a saving of over 200 hours, with grouting operations typically on the critical path for project completion, FoundOcean is reducing the time a construction vessel needs to be offshore.


FoundOcean


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www.windenergynetwork.co.uk


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