Patent Application
20240392526
The application relates to a foundation pile, in particular an offshore foundation pile, comprising a circumferential foundation wall extending in the longitudinal direction, wherein the foundation wall is bounded on the bottom side by a bottom-side end face and on the top side by a top-side end face, wherein the foundation wall is formed from a mineral building material. In addition, the application relates to a foundation pile set, installation tools and installation methods.
Offshore structures are increasingly being built, particularly at sea. For example, offshore wind farms with a large number of offshore wind energy structures are being installed to generate electrical energy or to provide electrical energy from so-called renewable energy sources. Compared to onshore locations, offshore locations are usually characterized by relatively continuous wind conditions and high average wind speeds, which means that offshore wind farms are increasingly being built.
As a rule, an offshore wind farm has a large number of offshore wind energy structures, such as a large number of offshore wind turbines, possibly a met mast and/or an offshore substation. The offshore wind farm can be electrically connected to an onshore transformer station or another offshore transformer station or offshore converter station via the offshore transformer station, for example. An onshore substation can in turn be connected to a public power grid.
An offshore wind turbine is designed to convert kinetic wind energy into electrical energy. Power cables in the form of submarine cables are laid to transmit the generated electrical energy between two offshore wind turbines or an offshore wind turbine and an onshore turbine.
For offshore wind energy structures, but also for other offshore structures (e.g. platforms for the exploration of gas and/or oil), it is common practice to anchor an offshore structure directly to or in the underwater subsoil, in particular a seabed, by means of a foundation (e.g. monopile, tripod, tripile or jacket foundations).
A foundation usually has a particularly cylindrical foundation pile or is formed by such a foundation pile. Preferably, a foundation pile can be formed in the form of a hollow structural element, i.e. in particular a hollow pile. A foundation pile generally has a circumferential foundation wall extending in the longitudinal or axial direction of the foundation pile, whereby the foundation wall is bounded on the bottom by a bottom end face and on the top by a top end face.
In practice, foundation piles are usually made of the metallic material steel. Steel is particularly suitable for this type of foundation due to its strength and rigidity properties. However, a foundation pile made of steel is associated with high costs. Furthermore, there are only a few manufacturers worldwide for offshore foundation piles made of steel. Finally, the high weight and risk of corrosion are disadvantages of a steel pile.
It was found that the construction of a foundation wall of a foundation pile from a mineral building material (e.g. concrete) has a large cost-saving potential compared to a (pure) steel structure. In addition, the lower weight—compared to a steel pile—and the better maintenance properties of such a foundation pile are an advantage. Furthermore, such a pile can be produced by a large number of manufacturers.
However, in order to provide sufficient strength in a concrete pile, it is necessary to increase the wall thickness of the foundation wall of the foundation pile compared to a hollow steel structure. Furthermore, the forces or loads exerted on the foundation pile made of a mineral building material during installation (for example by a pile-driving device or vibration devices) lead to difficulties. For example, higher forces can generally be exerted on a steel pile than on a concrete pile.
Three different installation methods are essentially known from the state of the art for driving a pile into the subsoil, in particular an underwater subsoil: Driving method, vibration method and drilling method.
The pile-driving method has proven to be particularly effective for foundations in the form of dense sands and/or clay. The driving impact exerted on the top face of a foundation pile by a driving tool results in a pressure wave that travels to the bottom face, i.e. the bottom pile tip, where it causes compaction of the subsoil in particular.
In addition to the high noise load, the high stress concentrations and deformation rates are a disadvantage of the pile-driving method, which can lead to material fatigue in particular. Furthermore, in an offshore structure it is usually necessary to attach, in particular to flange, a further foundation part, in particular a transition piece, to the upper end with the top face of the installed foundation pile. This places high demands on the manufacturing tolerances.
Compared to the driving method, the noise and stress loads are reduced with the vibration method, so that the resulting fatigue problems are also lower. Furthermore, the vibration method generally allows a foundation pile to be installed in the ground with a shorter installation time. In practice, however, if the subsoil is unfavorable (e.g. very firm), the vibration frequency transmitted to the foundation pile by the vibration tool may not be sufficient to bring the pile to a certain minimum depth (also called depth) or the energy required for this may increase significantly.
However, both the pile-driving and vibration methods have the disadvantage that it is usually not possible to drive the foundation pile into rocky ground.
The drilling method is particularly suitable for such subsoil. However, as the foundation pile diameter increases, the demands on the drilling tool increase enormously. In particular, it is necessary to construct a special drilling tool, which results in high costs. In practice, this means that drilling methods are only used for foundation piles with comparatively small external diameters and for rocky subsoil.
Other relevant criteria in an installation process are flange connections or grout connections, i.e. the connection between the foundation pile and the rest of the foundation.
Flange connections have the advantage of being less sensitive to weather conditions during installation, but there are diameter limitations. In addition, underwater installation is hardly possible, at least from an economic point of view. Furthermore, a flange connection requires regular inspection and monitoring.
Grout connections, on the other hand, are cost-effective and can also be produced under water. They also require little maintenance. However, there are also diameter limitations with a grout connection. Finally, the production of such a connection depends on the weather conditions.
From the explanations described above, it is clear that there is still a need to improve the installation process of a foundation pile, in particular an offshore foundation pile, but also of onshore foundation piles, and in particular to simplify and/or accelerate it.
Therefore, the present application is based on the task of creating a possibility with which an installation process of a foundation pile, in particular an offshore foundation pile, is improved and, in particular, the installation of a foundation pile is simplified and/or accelerated.
The problem is solved according to a first aspect of the application by a foundation pile, in particular an offshore foundation pile. The foundation pile comprises a circumferential foundation wall extending in the longitudinal direction, the foundation wall being bounded on the underside by an underside end face and on the upper side by an upper-side end face. The foundation wall is made of a mineral building material. A plurality of channels running essentially collinear to the foundation pile axis are integrated into the foundation wall. At least some of the plurality of channels each have an upper opening on the top end face.
By providing, in contrast to the prior art, a foundation pile, in particular an offshore foundation pile, made of a mineral building material, in which a plurality of channels, i.e. at least two channels, are integrated in the foundation wall, a possibility is created with which the installation process of the foundation pile can be significantly improved. In particular, a foundation pile with a plurality of collinear channels that are open at the top face allows easier and/or faster installation of such a pile, even though it is made of a mineral building material (and not steel).
As will be described in detail, for example, the plurality of channels may be filled with a liquid medium during the installation process and an installation tool may, for example, apply a driving impact to the liquid medium so that the pressure wave generated moves (essentially only) through the channel to the lower end of the channel. This pressure wave is then transferred to the lower end of the foundation pile at the lower end of the channel. The loads on the foundation wall are considerably reduced.
Alternatively or additionally, as will also be described in more detail, a rod-shaped element can be arranged in the plurality of channels, which can be used to transmit the force generated by an installation tool during an installation process from the top end of the foundation pile to the bottom end of the foundation pile. Here too, the loads on the foundation wall are considerably reduced.
In particular, it has been recognized according to the application that a collinear channel in a foundation wall formed from a mineral building material can be used to enable force transmission through the channel from the top end of the foundation pile to the bottom end of the foundation pile.
Overall, a foundation pile in accordance with the application therefore enables easier and faster installation of the foundation pile, i.e. installation in a foundation soil with a certain minimum depth or depth.
The foundation pile according to the application is in particular an offshore foundation pile. An offshore foundation pile means, in particular, a pile that is under water or installed in an underwater area in an installation state, i.e. when the foundation pile is installed at a certain depth in the subsoil. An offshore foundation pile is therefore designed for permanent use under water.
An offshore foundation pile is in particular a part of an offshore structure and is preferably used to support an offshore facility of the offshore structure. An offshore structure is preferably an offshore wind power structure, such as an offshore wind turbine, an offshore met mast or an offshore transformer station. Furthermore, an offshore structure can be a drilling or production platform or another offshore platform, preferably set up for the extraction, conversion and/or storage of energy, such as an offshore plant for the production of hydrogen.
As described above, an offshore structure may comprise an offshore facility, which may be secured by the foundation pile in an underwater seabed or foundation, in particular a seabed.
It is understood that the foundation pile can also be an onshore foundation pile or can be used onshore.
The foundation pile according to the application is formed in particular in the form of a cylindrical hollow structural element. Preferably, the foundation pile is a hollow pile.
The foundation pile has a circumferential foundation wall extending in the longitudinal or axial direction of the foundation pile. The foundation pile can preferably have a circular cross-sectional area. In other variants of the application, a different cross-sectional area may also be provided, such as an oval-shaped cross-sectional area. Furthermore, the application also includes, in particular, disintegrated structures consisting of several piles that tie into the ground, such as jackets, tripods and tri-piles.
The foundation wall (or foundation pile) can have two distal ends, each of which is bounded by end faces. A first end face can be a top end face and a second end face can be a bottom end face.
The top and bottom (or top and bottom) are defined in particular by the position of the foundation pile in the final installation state. In the installation state, the lower end face is in particular arranged in the subsoil, i.e. founded. The upper end face can in particular protrude at least from the ground surface, for example even from the waterline.
A foundation wall is defined in particular by an inner wall or inner side and an outer wall or outer side. In other words, a foundation wall has an inner diameter and an outer diameter. The foundation wall is the outer boundary of the foundation pile. In particular, the foundation wall is tubular. As already described, the foundation wall can be round, elliptical or oval in cross-section. A hollow cylindrical shape can increase the structural integrity so that the foundation pile can absorb higher bending moments.
The wall thickness of the foundation wall can preferably be essentially the same or constant from the top end face to the bottom end face. In other words, the wall thickness preferably remains the same over the entire length of the foundation wall, i.e. in particular it does not change over time.
In other variants of the application, the wall thickness of the foundation wall can also change, for example tapering from the top end face to the bottom end face (continuously or in steps), whereby the inner diameter of the foundation pile increases in particular as a result of the tapering and/or the outer diameter of the foundation pile decreases as a result of the tapering.
The foundation wall according to the application is formed or manufactured from a mineral building material. According to one embodiment of the foundation according to the application, the mineral building material may contain cement, at least in part. The mineral building material is preferably concrete, which is mixed from cement, gravel, sand and water and, in particular, is hardened after casting.
According to the application, a plurality of channels is integrated in the foundation wall, i.e. at least two channels. Preferably, two to one hundred collinear channels can be integrated in the foundation wall, particularly preferably between 20 and 60 channels.
The plurality of channels runs essentially collinear, i.e. in particular parallel to the foundation pile axis. One channel, preferably all channels, run at least essentially from the top end face to the bottom end face. In particular, the length of a channel corresponds to at least 80% of the length (in z-direction) of the foundation pile, preferably at least 90%, particularly preferably at least 95%. In one embodiment, the length of a channel can be identical to the length of the foundation pile.
The cross-sectional shape of a channel is preferably circular. In variants of the application, a channel can also have a different cross-sectional shape, such as an elliptical, triangular, rectangular, etc. shape.
At least part of the plurality of channels (i.e. at least one channel) has an opening on the top end face. This means in particular that the channel is accessible from the top end face. For example, the channel can be filled with a medium through the upper opening and/or an object (e.g. a rod-shaped element, piston) can be inserted into the channel through the upper opening and/or protrude (out) through the upper opening.
Preferably, all channels are open at their respective upper ends.
It is understood that a (lower or upper) opening of a duct may be temporarily closable, for example to protect the duct during transportation or after completion of the installation.
According to a further embodiment of the foundation pile according to the application, at least a part of the plurality of channels (preferably all channels of the plurality of channels) can each have a bottom opening on the underside end face. This means in particular that the channel is accessible from the bottom end face. For example, an object (e.g. a rod-shaped element) can protrude through the bottom opening.
According to an alternative embodiment of the foundation pile according to the application, a part of the plurality of channels (preferably all channels of the plurality of channels) may not be open or closed at the bottom end face. The advantage of a channel closed at the underside end face is, for example, that a channel can be filled with a liquid medium and this cannot escape at the underside end face.
A channel can have a constant cross-sectional area. According to a preferred embodiment of the foundation pile according to the application, a cross-sectional area of a channel can be reduced or tapered (continuously or in steps) in the direction of the bottom end face. In particular, the cross-sectional area can be at a maximum in the area of the upper opening. Starting from this point, the cross-sectional area can taper down to the lower (open or closed) end of the channel. The advantage of such a channel structure is, in particular, that a force transmitted via a liquid medium is not only introduced into the foundation wall at the closed end of the channel, but is already distributed along the course of the channel. In particular, the pressure can be transmitted in a distributed manner. In particular, a pressure wave can be transmitted to the foundation wall in stages.
Particularly preferably, the cross-sectional area of the channel in an upper third of the foundation pile can be reduced by at least 25%, preferably by at least 50% (and in particular by at most 80%). In this case, the foundation wall can preferably be reinforced (only) in the upper third of the foundation pile. In order to provide such reinforcement, a mineral building material with a compressive strength of more than 120 N/mm2 and/or a w/c ratio of less than 0.29 at least can preferably be used in the upper third.
In other words, an ultra-high performance concrete (UHPC; also known as ultra-high performance concrete) can be used as a mineral building material in the area of the upper third of the foundation pile. This can provide sufficient strength. In particular, a mineral building material with a yield strength (yield point) between 120 and 200 MPA, preferably between 140 and 200 MPA (with a 0.2% yield strength) can be used.
In order to improve the stability of a channel in particular, according to a further embodiment of the foundation pile according to the application, a lining can be arranged on the inner wall of a channel. The lining can in particular be made of metal (preferably steel). Preferably, each channel can be provided with a corresponding lining.
According to a particularly preferred embodiment of the foundation pile according to the application, at least one rod-shaped element can be arranged in a channel (of the plurality of channels). Preferably, in this embodiment, a rod-shaped element can be arranged in each channel. The rod-shaped element advantageously serves to transmit force from an upper end of the rod-shaped element to the lower end of the rod-shaped element. Preferably, the rod-shaped element can be made of metal (preferably steel). In particular, the rod-shaped element can be a metal rod, preferably a steel rod.
The cross-sectional shape of the rod-shaped element can preferably be circular. In other variants of the application, the rod-shaped element may also have a different cross-sectional shape, such as an elliptical, triangular, rectangular, etc. shape.
According to a further preferred embodiment of the foundation pile according to the application, a driving element can be arranged at the lower end of the rod-shaped element below the underside end face. In particular, the rod-shaped element can protrude from the lower opening of the channel. At the lower end of the rod-shaped element, the rod-shaped element can be connected to a pile-driving element (with a material bond). For example, the ramming element can be welded on.
Preferably, the ramming element can be (completely) made of metal, in particular steel. The ramming element is in particular a ramming shoe (also called driving shoe). Preferably, a steel rod with a steel ramming element arranged at the lower end can be provided.
The ramming element can preferably have a shape corresponding to the cross-sectional shape of the foundation wall. A pile-driving element in the form of a circumferential retaining wall has proven to be particularly advantageous for the displacement of soil material.
A wall thickness of the foundation wall can be at least greater than a wall thickness of the pile-driving element wall. The wall thickness of the foundation wall can be between 100 mm and 900 mm, preferably between 125 mm and 450 mm. The wall thickness of the piling element wall can be between 10 mm and 100 mm, preferably between 30 mm and 80 mm.
Preferably, the wall thickness of the foundation wall can be 1.5 times to 40 times greater than the wall thickness of the piling element wall. For example, the wall thickness of the pile-driving element wall can change in the longitudinal direction. In particular, the lower end of the driving element can be tapered in order to further simplify the displacement of the soil material.
Furthermore, a wall thickness of the ramming element can taper from the upper end of the ramming element to the lower end of the ramming element (continuously or in steps). Preferably, the ramming element can have a wedge shape. In particular, the wedge shape also includes rounded versions of the wedge tip.
In one embodiment, the outer diameter of the driving element can correspond to the outer diameter of the foundation pile, while the inner diameter of the driving element can be larger than the inner diameter of the foundation pile. Alternatively, the outer diameter of the driving element can be smaller than the outer diameter of the foundation pile, while the inner diameter of the driving element can correspond to the inner diameter of the foundation pile.
By arranging at least one driving element on the bottom end face, to which a force can be transmitted by a rod-shaped element guided through the channel (and therefore not via the foundation wall itself), a foundation pile formed from a mineral building material can be installed more easily. The load on the foundation pile wall during installation can be significantly reduced.
Furthermore, in the case of a preferred plurality of rod-shaped elements, each of these rod-shaped elements can be connected to a separate ramming element.
Alternatively, in the case of a preferred plurality of rod-shaped elements, at least two of these elements can be connected to the same (common) ramming element. In particular, a circumferential, one-piece ramming element can be provided, to which all rod-shaped elements are (materially) connected. In this embodiment, a force can be applied simultaneously to the upper ends of the plurality of rod-shaped elements and this force can be transmitted evenly to the common ramming element attached to the respective lower ends.
According to a further embodiment of the foundation pile according to the application, a lower damping element can be arranged between the underside end face and the at least one driving element. The lower damping element can preferably be formed from an elastic material, in particular an elastomer material (e.g. rubber or the like).
According to a further preferred embodiment of the foundation pile according to the application, a drill head can be arranged at the lower end of the rod-shaped element below the underside end face (at least during the installation process). In particular, as an alternative to a driving element, a drilling element in the form of a drill head can be attached to the lower end of a rod-shaped element. In particular, the rod-shaped element can protrude from the lower opening of a channel. At the lower end, the rod-shaped element can be connected to the drill head (with a material bond). For example, the drill head can be welded on.
A rotational movement can be transmitted to the drill head via the rod-shaped element. The foundation pile can be installed using a drilling method, particularly in the case of a large number of channels with drilling elements arranged in each channel (i.e. rod-shaped elements each with a drill head).
The drill head can preferably be made of metal, in particular steel.
A particular advantage of such an embodiment is that a large number of small drilling elements (consisting of a rod-shaped element and a drill head) are used instead of a single drilling tool with a considerable diameter. Special production of a drilling tool is not necessary. The costs can be significantly reduced.
In a particularly preferred variant, the drill head can be foldable or collapsible. In particular, the drill head can be folded in after installation of the foundation pile in such a way that the rod-shaped element together with the drill head can be removed from the channel.
According to a further embodiment of the foundation pile according to the application, the upper end of the rod-shaped element can be connectable or couplable to an installation tool (e.g. drilling device, pile-driving device and/or vibration device), which is set up for inserting the foundation pile into a subsoil (in particular an underwater subsoil), during an installation process. In particular, the upper end of the rod-shaped element corresponds to the installation tool in such a way that a mechanical coupling can be established between these elements. In particular, this means that a force and/or movement generated by the installation tool can be transmitted to the rod-shaped element via the established active connection.
In a further embodiment of the foundation pile according to the application, an upper damping element can be arranged on the upper end face. The damping element can preferably be formed from an elastic material, in particular an elastomer material (e.g. rubber or the like).
As already described, according to a preferred embodiment of the foundation pile according to the application, one channel (preferably all channels) can be filled with a liquid medium at least during the installation process. The liquid medium can in particular be a water-based and incompressible medium. For example, the medium can be (pure) water, a bentonite-water mixture or the like.
In addition, one channel of the plurality of channels (preferably all channels) can be filled with a hardenable material (e.g. grout) after installation. As described, a possibly existing rod-shaped element may have been removed beforehand, but may also remain in the channel.
According to a further embodiment of the foundation pile according to the application, the foundation pile can be made of a plurality of sheet pile walls, which are arranged in particular in an essentially circular or elliptical manner. Optionally, the sheet pile walls can be formed as a composite, with an inner surface and an outer surface which are clad with concrete.
For good load-bearing capacity, it has been found that the water-cement ratio (w/c) of the mineral building material can be less than 0.45, in particular less than 0.35 and preferably less than 0.3.
The moments and shear forces that occur in offshore wind turbines in particular can be adequately absorbed by the foundation pile, especially if the mineral building material has a strength class of at least C40/50, preferably C70/85, particularly preferably C100/115 according to EN 206 and EN1992.
Sufficient long-term stability of the foundation pile over the service life of an offshore structure, in particular an offshore wind turbine, especially with permanent penetration by water, can be achieved in particular by the mineral building material having a pore content (air voids) of less than 5%, preferably less than 3%, in particular less than 2%. The total porosity measured with mercury pressure porosity should be P28d<12% by volume after 28 days and P90d<10% by volume after 90 days.
Particularly in the case of permanent penetration of water during installation of the foundation pile, a sufficient service life can be achieved by ensuring that the mineral building material has a porosity of P28d<12 vol % in a mercury pressure porosimetric measurement, as described above. P28d is a measurement over 28 days. The porosity is also preferably less than 10% by volume. At P90d, i.e. for a measurement over 90 days, the porosity is preferably <10% by volume, in particular <8% by volume.
A sufficient load-bearing capacity of the foundation pile can be achieved in particular by the mineral building material having a cement content of at least 350 kg/m3, preferably at least 450 kg/m3, in particular preferably at least 650 kg/m3.
The foundation wall can also be mechanically prestressed. The pre-tensioning can press over cracks and thus keep the surfaces largely free of tensile stress. This is particularly advantageous with fluctuating torque loads. The prestressing force is preferably 5%, in particular more than 15%, greater than the compressive strength of the foundation wall. The pre-tensioning force is preferably applied in the longitudinal direction.
According to a further embodiment, the mineral building material can be (metallically) reinforced for even greater stability, particularly under dynamic environmental conditions. The metallic reinforcement is in particular a steel reinforcement. The reinforcement can be provided by fibers or reinforcing bars. Fiber reinforcement can also be achieved using carbon fiber, glass fiber or metal fiber.
The reinforcement can be formed in such a way that it has a concrete cover of at least 26 mm, preferably at least 40 mm, at 90% of the measuring points, preferably at 98% of the measuring points.
The mineral building material can be reinforced with ferritic stainless reinforcing steel. The reinforcement may not exceed a chromium content of 18 M %. The reinforcement may contain molybdenum components.
The mineral building material can be reinforced with austenitic stainless reinforcing steel. The reinforcement may contain at least 5 M %, in particular between 5 M % and 14 M % nickel and/or between 12 M % and 22 M %, in particular 15 M % to 20 M % chromium.
The mineral building material can be reinforced with ferritic-austenitic stainless reinforcing steel. The reinforcement can have at least 18 M %, in particular between 15 M %-20 M % chromium and 2 M %-8 M % nickel and optionally molybdenum.
According to a further embodiment, it is proposed that the mineral building material can be sealed for increased stability, in particular with a sealing foil. Such a sealing foil can, for example, be an aluminum-butyl scaling foil.
The foundation pile should preferably have an embedment length of at least 7 m. This may be sufficient to ensure that the foundation pile is sufficiently anchored in the ground. Binding lengths between 7 m and 20 m are preferred.
Another aspect of the application is a foundation pile set, comprising:
Preferably, the foundation pile set can comprise a plurality of (previously described) rod-shaped elements, in particular one rod-shaped element per channel. As already described, a rod-shaped element can be connected to a drill head or a driving element.
According to one embodiment of the foundation pile set according to the application, the foundation pile set can comprise at least one first tool adapter. The first tool adapter can in particular provide a coupling between the upper ends of the rod-shaped elements, which protrude from the upper end face from the channels, and an installation device. In particular, all upper ends of the rod-shaped elements can be coupled together with the installation device (e.g. ramming device, vibration device and/or drilling device) via the first tool adapter. In the case of a pile-driving device, the first tool adapter is used in particular to transmit a pile-driving impact simultaneously to all rod-shaped elements. In particular, a ring-shaped first tool adapter (e.g. in the form of an anvil) can be provided.
Another aspect of the application is a foundation pile set, comprising:
Preferably, a piston can be conical in shape and/or have a bearing to seal the upper opening.
A further aspect of the application is a method (in particular a driving method) for installing a foundation pile, in particular a previously described foundation pile, wherein a plurality of channels extending substantially collinear to the foundation pile axis is integrated in a foundation wall of the foundation pile and at least a part of the plurality of channels each has an upper opening at the top end face. The method comprises
The channels can preferably be closed or sealed at the lower end.
The liquid medium is in particular an incompressible medium, such as water or a bentonite-water mixture or the like.
The insertion of the at least one piston of an installation tool corresponding to the at least one upper opening into the respective opening takes place in particular in such a way that the piston contacts the liquid medium. In this method, the installation tool can in particular comprise a ramming device (e.g. a hydraulic hammer) set up to generate a ramming impact. In particular, this can be transferred to the liquid medium by the piston.
The second tool adapter described can advantageously be used in this process.
A foundation pile made of a mineral building material can be inserted into the ground in a simple manner.
A further aspect of the application is a method (driving and/or vibration method) for installing a foundation pile, in particular a previously described foundation pile, wherein a plurality of channels extending substantially collinear to the foundation pile axis is integrated in a foundation wall of the foundation pile and at least a part of the plurality of channels each has an upper opening at the upper end face and a lower opening at the lower end face, wherein a rod-shaped element is arranged in a channel, wherein a ramming element is arranged at the lower end of the rod-shaped element below the lower end face, wherein the method comprises:
In this method, a corresponding plurality of rod-shaped elements is preferably located in a plurality of channels, as has already been described. In this method, the first tool adapter can preferably be used to (temporarily) couple a pile-driving device or a vibration device of the installation tool to the upper ends of the rod-shaped elements, as already described.
According to a preferred embodiment of the method according to the application, when generating vibrations by the installation tool, the method may further comprise:
In this case, the installation tool can be a combined pile-driving and vibration tool, as will be described in more detail. While the vibrations or oscillations generated by a vibration device are transmitted to the rod-shaped elements, the pile-driving impacts carried out by a pile-driving device can be exerted on the foundation wall at the same time. The installation of a foundation pile is significantly accelerated by this particularly preferred combination.
A further aspect of the application is a method (drilling and possibly driving method) for installing a foundation pile, in particular a foundation pile described above. pile) for installing a foundation pile, in particular a foundation pile described above, wherein a plurality of channels extending substantially collinear to the foundation pile axis is integrated in a foundation wall of the foundation pile and at least a part of the plurality of channels has an upper opening at the upper end face and a lower opening at the lower end face, wherein a rod-shaped element is arranged in the channel, wherein a drilling head is arranged at the lower end of the rod-shaped element below the lower end face, wherein the method comprises:
In this (drilling) process, there is preferably a corresponding plurality of rod-shaped elements in a plurality of channels, as already described.
According to a preferred embodiment of the method according to the application, the method may further comprise:
In this case, the installation tool can be a combined pile-driving and drilling tool, as will be described in more detail. While a rotational movement of a drilling device can be transferred to the rod-shaped elements, pile-driving impacts from a pile-driving device can be exerted on the foundation wall at the same time. The installation of a foundation pile can be significantly accelerated by this particularly preferred combination.
A further aspect of the application is an installation tool for driving a foundation pile, in particular a foundation pile described above, into a foundation soil, wherein a plurality of channels extending substantially collinear to the foundation pile axis is integrated in a foundation wall of the foundation pile and at least a part of the plurality of channels has an upper opening at the upper end face and a lower opening at the lower end face, wherein a rod-shaped element is arranged in the channel, wherein a ramming element is arranged at the lower end of the rod-shaped element below the underside end face, wherein the installation tool comprises:
The installation tool according to the application is in particular a combined pile-driving and vibration tool with a first tool adapter, preferably in the form of an anvil. The first tool adapter can in particular be operatively connected to the pile-driving device. For example, an anvil can have a stop or contact surface on its underside, which rests at least partially on the upper face of the foundation pile during the installation process, i.e. contacts it. The pile-driving device, also known as an impact hammer or pile-driving hammer (e.g. a hydraulic hammer), can exert pile-driving impacts on the upper side of the anvil (in a conventional manner), which can be transferred to the foundation wall by the anvil via the contact surface.
Furthermore, the first tool adapter has at least one feed-through opening. In particular, at least one feed-through opening can be provided in the first tool adapter for each rod-shaped element of a foundation pile to be installed. The feed-through opening is located in particular in the area of the stop surface or the stop surface is located around the feed-through openings.
In particular, a feed-through opening has an internal diameter that is at least larger than the external diameter of a rod-shaped element.
During the installation process, the at least one rod-shaped element (preferably all rod-shaped elements) is guided through the feed-through opening. The upper end of a rod-shaped element is coupled to the vibration device during the installation process in such a way that the vibrations or oscillations generated are transmitted to the rod-shaped element (in the manner described above). The installation of a foundation pile can be significantly accelerated.
A vibration device can be set up to generate vibrations or a pulse sequence in the vertical direction (i.e. in the longitudinal direction of the inserted pile). For example, the vibration device can have an eccentric device that can be driven by a drive of the vibration device. The eccentrics of the eccentric device, which are arranged in pairs in particular, can preferably rotate at the same angular speed, but in opposite directions. The at least two eccentrics can generate centrifugal forces. The horizontal forces can cancel each other out, while the vertical components can add up to a total centrifugal force. The pulses or vibrations generated in this way can be transmitted to the ramming element due to the frictional connection between the vibration device and the rod-shaped elements. In particular, a large number of impulse or strain waves are generated by the vibration device.
A further aspect of the application is an installation tool for inserting a foundation pile, in particular a foundation pile described above, into a foundation soil, wherein a plurality of channels extending substantially collinear to the foundation pile axis is integrated in a foundation wall of the foundation pile and at least a part of the plurality of channels each has an upper opening at the upper end face and a lower opening at the lower end face, wherein a rod-shaped element is arranged in the channel, wherein a drill head is arranged at the lower end of the rod-shaped element underneath the lower end face, wherein the installation tool comprises:
A pile-driving device designed to generate pile-driving impacts,
The installation tool according to the application is in particular a combined drilling and vibration tool with a (first) tool adapter, preferably in the form of an anvil. The first tool adapter can in particular be operatively connected to the ramming device. The first tool adapter can have a stop or contact surface on its underside, which rests at least partially on the upper end face during the installation process, i.e. makes contact with it. The ramming device (e.g. a hydraulic hammer) can exert ramming impacts or ramming blows on the upper side of the first tool adapter (in a conventional manner), which can be transferred to the foundation wall by the first tool adapter via the stop surface.
Furthermore, the first tool adapter has at least one feed-through opening. In particular, at least one feed-through opening can be provided in the first tool adapter for each rod-shaped element of a foundation pile to be installed. The feed-through opening is located in particular in the area of the stop surface or the stop surface is located around the feed-through openings.
In particular, a feed-through opening has an internal diameter that is at least larger than the external diameter of a rod-shaped element.
During the installation process, the at least one rod-shaped element (preferably all rod-shaped elements) is guided through the feed-through opening. The upper end of a rod-shaped element is coupled to the drilling device during the installation process in such a way that (in the manner described above) a generated rotational movement is transmitted to the rod-shaped element. The installation of a foundation pile can be significantly accelerated.
The installation tools described above can be used to install a foundation pile, in particular a foundation pile described above.
A still further aspect of the application is an offshore structure comprising a foundation pile as described above. The offshore structure comprises at least one offshore facility supported by the foundation.
The features of the foundation piles, offshore structures, foundation pile sets, installation methods and installation tools can be freely combined with each other. In particular, features of the description and/or of the dependent claims can be inventive in their own right, even by completely or partially bypassing features of the independent claims, in a sole position or freely combined with one another.
There are now a large number of possibilities for designing and further developing the foundation pile according to the application, the offshore structure according to the application, the installation tools according to the application, the foundation pile sets according to the application and the installation methods according to the application. For this purpose, reference is made, on the one hand, to the claims following the independent claims and, on the other hand, to the description of embodiments in conjunction with the drawing.
The drawing shows:
In the following, similar reference symbols are used for similar elements. Z also refers to the vertical axis and x and y to horizontal axes. Furthermore, in the present application, the expressions “bottom”, “lower”, “bottom-sided” etc. and “top”, “upper”, “top-sided” etc. refer in particular to the vertical axis z and in particular to the installation state of the foundation pile, i.e. when the foundation pile is installed in the subsoil.
The offshore foundation pile 100 (hereinafter generally referred to as foundation pile for short) is a hollow pile 100 with a circular cross-sectional shape in the present case. In other variants of the application, other cross-sectional shapes may also be provided.
The foundation pile 100 has a circumferential foundation wall 102 extending in the longitudinal direction or along the foundation pile axis 114. The foundation wall 102 is bounded on the bottom side by a bottom-side end face 118 and on the top side by a top-side end face 116. The foundation wall 102 encloses an inner space 108.
The foundation wall 102 is preferably made of concrete (as described above), in particular cast from concrete.
As can be seen in particular from
In other variants of the application, the wall thickness of the foundation pile can change. For example, the wall thickness can taper from the top end face to the bottom end face, for example by increasing the inner diameter while the outer diameter remains constant and/or by reducing the outer diameter while the inner diameter remains constant.
According to the application, a plurality (in the present example two) of channels 110 extending substantially collinear (i.e. substantially parallel) to the foundation pile axis 114 is integrated in the foundation wall 102. One channel 110 extends substantially from the top end face 116 to the bottom end face 118.
In particular, the length of a channel 110 corresponds to at least 80% of the length (in z-direction) of the foundation pile 100, preferably at least 90%, particularly preferably at least 95%. In one embodiment, the length of a channel can be identical to the length of the foundation pile.
At least some of the plurality of channels 110 each have an upper opening 112 on the upper end face 116. In the present case, all channels 110 are open at their upper end, i.e. accessible. In particular, the channels 110 are in the present case only accessible through the respective upper openings 112. As will be described in more detail, this enables objects/media to be inserted/filled into a channel.
In the present embodiment example, the channels 110 are closed at their lower ends, i.e. at the bottom end face 118, or have no opening. Furthermore, in the present embodiment, the cross-sectional area from the upper end of a channel 110 to the lower end of the channel 110 can remain constant.
The cross-sectional shape of a channel 110 can in principle be arbitrary, for example, as shown, circular, oval, rectangular, triangular, substantially “(”-shaped (whereby the curvature can correspond to the curvature of the pile), etc.
As can be seen, a large number of channels 210 are provided in the present case. Preferably, the number of integrated channels 210 can be between 20 and 60.
Preferably, the respective distance 222 between two adjacent channels 210 may always be the same. In other words, the channels 210 can preferably be arranged equally distributed in a circumferential direction of the foundation wall 202. In particular, this enables a uniformly distributed application of force in the foundation pile 200.
With regard to the following embodiments, it should be noted that the foundation pile always has a number of channels, even if only a single channel is shown for a better overview.
As can be seen in
As an example, the channel 310 is filled with a liquid medium 332, e.g. water or a water mixture. If a force F is now exerted on the liquid medium 332 by an indicated piston 334 (for example by a ramming impact), a pressure wave is generated which propagates substantially through the liquid medium in the direction of the underside end face 318. As indicated by the arrows labelled F1, F2 and F3, a portion of the force exerted by the piston 334 is transmitted to the foundation wall 302, particularly at the steps and at the closed lower end of the channel 310.
A distributed application of force to the foundation wall 302 can be provided. This allows the load to be distributed and thus reduced. Furthermore, a displacement of soil material can be achieved during an installation process.
Preferably, the cross-sectional area of the channel 310 in an upper third 328 of the foundation pile 300 may be reduced by at least 25%, preferably by at least 50% (and in particular by at most 80%). In this case, the foundation wall 302 may preferably be reinforced (only) in the upper third 328 of the foundation pile 300, as already described.
The main difference to the previous embodiment example according to
Optionally, the channel 410 (preferably each channel 410) is provided with a lining 436. Thus, in the present case, a lining 436 is arranged on the inner wall of the duct 410. The lining 436 may be formed of metal, preferably steel. It is understood that the lining may also be omitted and/or present in other variants (such as
First of all, it can be seen from
In addition, a rod-shaped element 540 is arranged in a channel 510. Preferably, a rod-shaped element 540 can be arranged in each channel 510. In particular, the rod-shaped element 540 is arranged movably in the channel 510, at least during the installation process. Preferably, the rod-shaped element 540 is formed from steel, in particular a steel rod 540.
Preferably, the upper end 542 of the rod-shaped element 540 protrudes through the upper opening 512, i.e. from the upper end face 516. In addition, the lower end 544 of the rod-shaped element 540 protrudes through the lower opening 552, i.e. from the lower end face 518.
At the lower end 544 of the rod-shaped element 540, a ramming element 546 is arranged below the underside end face 518. The ramming element 546 can be formed from metal, preferably from steel. In particular, the rod-shaped element 540 can be connected to the ramming element 546 by a material bond.
The ramming element 546 can preferably have a wedge shape. Furthermore, each rod-shaped element can be connected to a separate ramming element.
Preferably, in a preferred plurality of rod-shaped elements 510, at least two of these elements 510 can be connected to the same (common) ramming element 546. In particular, a circumferential, one-piece ramming element 546 can be provided, to which all rod-shaped elements 510 can be connected.
In this case, the ramming element 546 may have a (maximum) outer diameter that substantially corresponds to the outer diameter of the foundation wall 502. Preferably in addition, the ramming element 546 may have a (minimum) inner diameter that substantially corresponds to the inner diameter of the foundation wall 502.
In this embodiment, the plurality of rod-shaped elements 540 can be simultaneously subjected to a force at their upper ends 542 and transmit that force uniformly to the common ramming element 546 attached to the lower ends 544.
Optionally, a lower damping element 548 may be arranged on the foundation pile 500 between the bottom end face 518 and the at least one driving element 546. The lower damping element 548 may preferably be formed from a resilient material, in particular an elastomeric material (e.g. rubber or the like).
Furthermore, an upper damping element 550 may optionally be arranged on the foundation pile 500 on the upper end face 516. The upper damping element 550 may preferably be formed from a resilient material, in particular an elastomeric material (e.g. rubber or the like).
As can be seen, a drill head 656 is arranged at the lower end 644 of the rod-shaped element 640 below the underside end face 618. In particular, the rod-shaped element 640 can protrude from the lower opening 652 of the channel 610. At the lower end 644, the rod-shaped element 640 can be connected to the drill head 656 in a material-locking manner.
A rotational or rotary movement can be transmitted to the drilling head 656 via the rod-shaped element 640. In particular, in the case of a plurality of channels 640 with drilling elements arranged therein (i.e. rod-shaped elements 640 each with drilling head 656), the foundation pile 600 can be installed by a drilling method.
The drill head 656 can preferably be formed from metal, in particular steel, and in particular be designed to be retractable, as has already been described.
Although the cross-sectional area of the channels in
After an installation process, the respective rod-shaped element together with the ramming element or drill head can remain in the respective channel or alternatively be removed and, in particular, reused.
The second tool adapter 760a (e.g. an anvil 760a) is formed in the present case from a (circular) base body 764 and a plurality of pistons 730 (or projections), the number and position of the pistons 730 corresponding in particular to the number and position of the plurality of channels 718 or upper openings 712 of the channels 710.
Preferably, a piston 730 can be conical in shape and/or have an optional bearing for scaling the upper opening. An upper damping element can also optionally be arranged.
A pile-driving device 762 (shown in very simplified form) can be used to exert a pile-driving impact or pile-driving blow on the second tool adapter 760a. As has been described, the foundation pile 700 in particular can be driven into the subsoil in this way (see also the comments on
The installation tool can be formed by ramming device 762 and the second tool adapter 760a.
In particular, a first tool adapter 760b is provided. The first tool adapter 760b can in particular provide a coupling between the upper ends of the rod-shaped elements 740, which protrude from the upper end face 716 from the channels 710, and that of the (very simplified) ramming device 462.
In particular, all upper ends of the rod-shaped elements 740 can be placed in an operative connection or (temporarily) coupled together with the ramming device 762 via the first tool adapter 760b. In the case of a ramming device 762, a ramming impact is transmitted in particular by the first tool adapter 760b simultaneously to all rod-shaped elements 740 and via this to the at least one ramming element 746. In particular, a ring-shaped first tool adapter 760b (e.g. an anvil) can be provided.
The installation tool 770 can be formed by the ramming device 762 and the tool adapter 760b.
The installation tool 870 shown in
In particular, the anvil 860 can be in an operative connection with the ramming device 862. This means that the ramming device 862 (e.g. a hydraulic hammer) can exert ramming impacts on the anvil 860.
The anvil 860 can have an abutment or contact surface 890 on its underside, which at least partially rests on the upper end face 816 of the foundation pile 800 during the installation process, i.e. contacts it. The ramming device 862 can exert ramming impacts or ramming blows on the upper side of the anvil 860, which can be transferred by the anvil 860 via the stop surface 890 to the foundation wall 802.
Furthermore, the anvil 860 has at least one feed-through opening 868. In particular, at least for each rod-shaped element 840 of a foundation pile 800 to be installed, a respective feed-through opening 868 can be provided in the anvil 860. The feed-through opening 868 is located in particular in the region of the stop surface 890 or the stop surface 890 is located around the feed-through openings 868.
In particular, a feed-through opening 868 has an inner diameter that is at least larger than the outer diameter of a rod-shaped element 840. During the installation process, the at least one rod-shaped element 840 (preferably all rod-shaped elements 840) is guided through the feed-through opening 868. During the installation process, the upper end of a rod-shaped element 840 is coupled to a vibration device 866 in such a way that the vibrations or oscillations generated by the vibration device 866 are transmitted to the rod-shaped element 840.
Vibrations and driving impacts can be generated simultaneously during the installation process. While the load on the foundation wall can be reduced, the installation of the foundation pile can be significantly accelerated at the same time.
The installation tool 970 is in particular a combined drilling and vibration tool 970, preferably with a (first) tool adapter 960 in the form of an anvil 960. The anvil 960 can in particular be formed essentially in accordance with the previous anvil 860 of
During the installation process, the at least one rod-shaped element 940 (preferably all rod-shaped elements) can be guided through the feed-through opening 968. During the installation process, the upper end of a rod-shaped element 940 is coupled to a drilling device 967 of the installation tool 970 in such a way that a generated rotational movement is transmitted to the rod-shaped element 940.
Rotation and driving impacts can be generated simultaneously during the installation process. While the load on the foundation wall can be reduced, the installation of the foundation pile can be significantly accelerated at the same time.
The offshore structure 1080 shown here is an offshore wind power structure 1080 in the form of an offshore wind turbine 1080. In the present case, the offshore structure 1080 and thus also the foundation pile 1000 are shown in an installation state. The following explanations can be easily transferred to other offshore structures.
The offshore structure 1080 comprises the foundation pile 1000 and at least one offshore device 1072 (e.g. tower, intermediate piece, nacelle, rotor, generator, etc.).
As has already been described,
A plurality of channels running essentially collinear to the foundation pile axis are integrated into a foundation wall of the foundation pile to be installed and at least some of the plurality of channels each have an upper opening on the top end face. The lower end of the respective channel can in particular be closed.
In a step 1101, the foundation pile is made available at an installation site. For example, the foundation pile can be transported to a specific offshore location by a watercraft. The foundation pile can then be positioned (vertically) on the subsoil, in particular an offshore subsoil, for installation, for example by means of a crane.
In a step 1102, the majority of the channels (in particular all channels) are filled with an (incompressible) liquid medium, for example water or a bentonite-water mixture. In particular, a channel can be at least almost completely filled with the liquid medium.
In a step 1103, at least one piston of an installation tool corresponding to the upper opening of a channel is inserted into this upper opening, so that in particular the piston contacts the liquid medium, as shown for example in
In a further step 1104, the installation tool (in particular a ramming device) exerts a force on the piston in such a way that a pressure wave is transmitted to the liquid medium. In particular, ramming impacts can be exerted. The step 1104 can be carried out until a certain embedment depth is reached. The installation tool can then be removed again. Optionally, the channels can be filled with a hardenable medium, such as grout.
A plurality of channels extending substantially collinear to the foundation pile axis is integrated in a foundation wall of the foundation pile and at least some of the plurality of channels each have an upper opening on the upper end face and a lower opening on the lower end face. A rod-shaped element (permanent or temporary) is arranged in a channel (preferably each channel), with a pile-driving element being arranged at the lower end of the rod-shaped element below the underside end face.
In a step 1201, the foundation pile is made available at an installation site. For example, the foundation pile may be transported to a specific offshore location by a watercraft. The foundation pile can then be positioned (vertically) on the subsoil, in particular an offshore subsoil, for installation, for example by means of a crane.
In step 1202, the upper end of the rod-shaped element is coupled to an installation tool. For example, the installation tool shown in
In step 1203, vibrations may be generated by the installation tool so that the generated vibrations are transmitted to the pile-driving element.
Alternatively, in step 1203, pile driving impacts may be generated by the installation tool so that the generated pile driving impacts are transferred to the pile driving element.
Step 1203 can be carried out until a certain embedment depth is reached. The installation tool and, if necessary, the rod-shaped elements can then be removed again. Optionally, the channels can be filled with a hardenable medium, such as Grout.
Furthermore, in the event that vibrations are generated by the installation tool, the method may preferably further comprise the step:
In particular, the vibrations and pile-driving impacts can be generated in parallel and transferred to the rod-shaped element or the foundation wall.
A plurality of channels extending substantially collinear to the foundation pile axis is integrated in a foundation wall of the foundation pile and at least a part of the plurality of channels on the upper end face has an upper opening and on the lower end face a lower opening. A rod-shaped element is arranged in the channel (preferably each channel), with a drill head being arranged at the lower end of the rod-shaped element below the underside end face.
In a step 1301, the foundation pile is provided at an installation site. For example, the foundation pile may be transported to a specific offshore location by a watercraft. The foundation pile can then be positioned (vertically) on the subsoil, in particular an offshore subsoil, for installation, for example by means of a crane.
In step 1302, the upper end of the rod-shaped element is coupled to an installation tool. Preferably, the installation tool according to
In step 1303, a rotational movement is generated by the installation tool so that the rotational movement is transferred to the drill head. Step 1203 can be carried out until a certain embedment depth is reached. The installation tool and, if applicable, the rod-shaped elements can then be removed again (e.g. a retractable drill head can be provided). Optionally, the channels can be filled with a hardenable medium, such as Grout.
Furthermore, the method may preferably further comprise the step of:
In particular, the rotations and ramming impacts can be generated in parallel and transferred to the rod-shaped element or the foundation wall.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2021 126 015.9 | Oct 2021 | DE | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/077415 | 9/30/2022 | WO |
