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Fatigue Resistant
Exagrout for Onshore
Wind Turbines
Product at a Glance
Typically MasterFlow 9300 is used in onshore installations Early designs of onshore wind turbine installations had towers
where the bottom flange of the turbine tower is to be grouted directly embedded into the concrete foundations, the so
and connected to the concrete foundations. called can design. Such installations have suffered major
problems like concrete cracking and poor load transfer,
The material has been especially formulated for onshore resulting in lower electricity production and even stand-still.
wind turbines:
§§ Grouting under the load transfer plate or T-flanges of More recent designs, more durable and reliable, use
pre-stressed towers pre-stressed ring or T-flanges that control and better distribute
§§ Grouting under harsh conditions and temperatures as any load acting on the foundation. This is the so-called
low as 2 °C anchor cage design. MasterFlow 9300 is especially designed
§§ All void filling from 30 to 200 mm where high early and to fill the gap between flange and concrete foundation, and
final strength, and fatigue resistance are required guarantee long term load transfer and electricity production.
Cold weather
High fatigue Excellent
application
resistance durability
More installation
Absorbing Guaranteeing longterm
opportunities and fast
dynamic loads electricity production
project completion
MasterFlow 9300 has been developed by Master Builders To meet the requirements of the designers and wind
Solutions experts especially to meet the highest requirements turbine suppliers, high early and final characteristic
of the turbine manufacturers and designers in onshore wind. strengths are required for long term durability of the grout
and thus complete installation.
Designs of the concrete foundation and the grout connecting
the turbine to the foundation are made to guarantee the Application of MasterFlow 9300 by BASF Licensed
minimum 25 years lifetime of the wind farm. High fatigue Contractors guarantees that the highly specialized grout
resistance of the grout is of utmost importance to guarantee material is correctly installed. Mechanical properties are
the long term transfer of all dynamic loads that are occurring therefore also secured on the jobsite.
over the lifespan of a wind turbine installation.
5
MasterFlow 9300
Fatigue Resistant Exagrout for Onshore Wind Turbines
Figure 2
The compressive strength of MasterFlow 9300 was tested
using variable size specimens ranging from 150 x 300 mm 2 ºC 5 ºC 10 ºC 20 ºC 30 ºC
140
120 Flexural strength – Tensile splitting strength –
100 Modulus of elasticity
80
60 The flexural strength of MasterFlow 9300 was measured
40 in accordance with EN 196-1 using 40 x 40 x 160 mm
20 prisms, while the splitting tensile strength was determined
0 according EN 12390-5 on 100 x 200 mm cylinders.
0 7 14 21 28
The static modulus of elasticity was measured in line with
Time (days)
EN 13412 using 100 x 200 mm cylinders.
Results obtained after 28 days of curing are summarized
Pre-stressing of the anchor bolts of the turbine installation in Table 1.
is very much dependent on the rapid strength development
of the grout. Figure 2 shows the early strength development
of MasterFlow 9300 at various temperatures between 2 °C Table 1
and 30 °C.
The grout strength requirement before tensioning the Flexural Tensile Static modulus
anchor bolts is around 50 MPa depending on the turbine strength splitting strength of elasticity
manufacturer and type. Such value is typically achieved (MPa) (MPa) (GPa)
with MasterFlow 9300 at 20 °C well within 24 hours, and in 21.6 7.6 44.9
approximately 48 hours at temperatures as low as 2 °C.
6
MasterFlow 9300
Fatigue Resistant Exagrout for Onshore Wind Turbines
Fatigue occurs when a material is subjected to repeated The observed number of cycles to failure in the tests under
loading and unloading. If the loads are above a certain cyclic loading corresponds well with the prediction
threshold, microscopic cracks will begin to form. Eventually according to DNV-OS-C502 (Figure 3). It can be concluded
a crack will reach a critical size, and the structure will that MasterFlow 9300 shows a performance under cyclic
suddenly fracture. loading that is as good as for reinforced concrete. Based
on the tests, it is concluded that the design for fatigue can
Fatigue equation according DNV-OS-C502 be carried out using formulations for fatigue life prediction
in DNV-OS-C502 for reinforced concrete.
The design standard DNV-OS-C502 gives design guidelines
for how to take into account maximum and minimum stress In the fatigue life calculations C5 = 0.85 shall be taken for
levels for fatigue life predictions. Fatigue calculations are MasterFlow 9300.
made according to the formulation:
Fatigue resistance
Figure 3
where:
100 %
90 %
C¹ = 12 for structures in air 80 %
Max relative stress (MPa),
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may affect processing and application of our products, do not relieve processors from carrying out their own investigations and tests. The agreed contractual quality of the product at the time of
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