This will have a beneficial effect on the composite strength, as well as the modulus of elasticity. The standard silica sand will be replaced with measured granite sawdust. The geopolymer cement (binder) will make up 20 percent of the cement mix. A new hybrid super-plasticizer has been designed for geopolymer cement using rice husk and an alkaline that makes it possible to achieve the correct viscosity for placing the mix. To achieve its workability, its placement will need a super plasticizer. The geopolymer cement has a high viscosity.
The mix must be efficient to wet-out and bind to the basalt rebar and the chopped basalt fiber for low temperature crack resistance. The key to constructability is the concrete mix design.
Basalt fiber, much like nylon fiber, is chopped into variable lengths (6-25mm) and used in the mix design for added strength. The geopolymer cement in the concrete binds to the basalt rebar on a chemical level in addition to its mechanical bonding. For a smaller diameter in steel rebar, basalt rebar is seven- to nine times lighter for an equal strength replacement. The threads are laid in parallel and locked together with an epoxy, producing basalt rebar: a waterproof, chemical-resistant, fireproof material with a tensile strength three times stronger than steel rebar. The basalt, when heated to a temperature of 1,800 degrees, liquifies and can be poured through a palladium die that produces soft, flexible threads.
Basalt (generic solidified volcanic rock) is found all over the Earth and is a key component of the mix, enabling the 100-year minimum durability of the foundation structure. To replace the steel rebar, a nonmetallic bar made from readily available basalt stone is used for reinforcement. The tower interface to the bottom is equal to 625 linear feet. In keeping with the climate accord of clean energy, the production of geopolymer cement has an 80 percent smaller carbon footprint then a standard OPC. In general, geopolymer cement (binders) are stronger bond well to most materials have minimal expansion or contraction are formable resistant to salts, acids, and alkalis and are fireproof and waterproof. This geopolymer binder can have as little as 2 percent calcium, producing a saltwater-resistant material. One of the most important new cement components is a geopolymer binder made up of four inexpensive and widely available ingredients: Class-F fly ash, fresh water, water-glass (sodium silicate), and lye (sodium hydroxide).
Sulphur compounds in seawater directly react with the large amounts of calcium (approximately 79 percent) in the OPC binder, essentially “rotting” the binder in the concrete, causing rapid failure. However, in the offshore wind industry, the concrete made from OPC (the binder) and coated steel rebar are not durable enough in this corrosive atmosphere. Ordinary Portland Cement (OPC) is the most widely produced man-made material on Earth. Construction MaterialsĬoncrete and rebar are extremely well understood materials backed by a thoroughly developed industry. A telescopic deployment system for the DDWTG, a novel design for a customized deployment vessel, and a round-the-clock 24/7 construction schedule result in a build-out of one complete spar buoy in just 15 days and its deployment in two days. This new SB will be the first to have a double wall hull and use innovative new concrete materials in a design mix that will ensure a minimum 100-year life in any sea state, providing a foundation substructure good for three generations of DDWTG. The key is a new large-scale spar buoy (SB) structural design, which is scalable and allows for only one construction formwork design to support and produce all the 10-MW to 20-MW floating foundation requirements. A new innovative floating foundation system with a unique deployment method will substantially reduce the levelized cost of energy of the DDWTG. Developers of clean energy are ready to deploy large, efficient 10-MW to 20-MW direct drive wind turbine generators (DDWTG) in far offshore, deep-water wind farms.