Completed construction of the DEOMAR prototype

Within the framework of the DEOMAR project, Rover Maritime has completed the manufacture of the full-scale Mockup prototype corresponding to a sector of the WHEEL offshore wind technology foundation tank. This prototype marks a key milestone within the DEOMAR project. This preliminary test, developed in coordination with Esteyco and BTP Infrastructures, has allowed the validation under real construction conditions of the processes and constructive challenges associated with the future execution of the definitive prototype of connection elements of tense lines, thus consolidating the viability and excellence of the construction process.

The Mockup has faithfully reproduced the conditions foreseen on site, being executed on a representative section of wall 8 meters wide, 10 m high and 34 cm thick, including a cross-section diaphragm in T. The prototype incorporates into its geometry an inferior plane of the Upper Tank (UT), a tie element for cables on docks and vessels, which is generally made of steel, but its concrete construction has been adapted in the DEOMAR project. This orbit functions as an anchor point between the two tanks. For the manufacture of the Mockup, 34 m3 of concrete were used to first verify the viability of the encoding system of the bites using negative molds, and then to analyze the behavior of the concrete in the face of the high armor density and the presence of the brassings. In addition, an innovative landfill system was validated that allowed a fluid and constant discharge rate from a height of 10 m.

Key validated constructive challenges

1. Singular geometry and high reinforcement density of the orbit

The construction of the Mockup has confirmed the feasibility of assembling the cuff, the iron and its correct integration with the negative mold intended to reproduce the grooves of the tendons. The execution of the test showed that both the design of the coffering and the assembly sequence are compatible with the deadlines and requirements of the work.

2. Validation of the special concrete used in this prototype

The test allowed to evaluate the behavior of concrete, under real conditions of manufacture, transport, pumping and installation in high levels of reinforcement and narrow geometries. Thanks to a thorough study of the design and control of the mixture, the material maintained its rheological properties during the operating window. It flowed homogeneously and showed excellent filling capacity without segregation or significant appearance of cockroaches.

3. Operation of the discharge system

El innovador sistema diseñado, demostró ser efectivo para evitar segregación por impacto y obstrucciones en zonas confinadas. especialmente relevante para muros de gran altura y elevada densidad de armadura.

4. Uncoiled, surface finish and geometric fidelity

After only 24 hours of curing, the deburring was carried out without incident and allowed to check a high quality finish, both in the wall cladding and in the geometry of the wall. The absence of any significant flaws or defects confirms the suitability of the dumping procedures and the concrete used.

A decisive step towards the full prototype of the WHEEL technology

The conclusions obtained by Rover Maritime in the construction of the MockUp will allow to adjust and optimize the planning of the work, the procedures of bending, ferrating and dumping. Also, thanks to the prototype it will be possible to calibrate the parameters of the final concrete during construction.

The success of the Mockup provides the technical security needed to move on to the next phase: the full-scale construction of the UT float with its tensile line connection elements that will form part of the DemoWheel prototype.