Design Report of Steel Pipe Pile Foundation (SPP)

Project : Trung Nam Tra Vinh Wind Power Plant Project

26/MAY/2020

Nippon Steel Corporation

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Ⅰ.Design condition
1. Load condition
(Load condition: SG4.5-145 CIIB HH107.5m)

1)Extreme

2)Fatigue

3)Quasi-Permanent

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2. Other design criteria

Based on customers requirement, we follow below table for consider Horizontal Stiffness (Khor) and Rotational
Stiffness (Kror). ＊This is for tower HH90m, not for HH107.5m

3. Soil condition
Based on soil data of HK-1
Scour: There is no data related to scour depth, thus we assume 4.0m for scour depth.

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Layer name Soil Layer Pile Average γ γ’ φ C

thickness length SPT-N
(m) (m) value (kN/m3) (kN/m3) (°) (kN/m2)
Projection - 6.0 6.1 - - - - -
1(Scour) CL Clay 4.0 4.1 - - - - -
1 CH Clay 4.0 4.1 2.2 17.24 7.71 7.03 9.8
2 CL Clay 7.8 7.9 2.0 15.90 6.03 3.68 9.8
3 CL Clay 2.0 2.0 2.0 16.31 6.78 5.01 9.8
4 CL Clay 2.6 2.6 21.0 17.78 8.44 15.48 28.42
5 SC Sand 4.5 4.6 16.0 18.39 9.25 18.46 20.58
7 SM/SC Sand 7.1 7.2 32.0 18.36 9.29 27.20 10.78
8 CL Clay 6.7 6.8 19.5 17.67 8.47 16.45 43.12
9 CL Clay 2.3 2.3 19.0 18.52 9.19 22.10 26.46
10 CH Clay 3.1 3.1 20.0 18.28 8.97 17.40 49.98
11 CL Clay 7.5 7.6 31.0 18.00 8.70 21.32 27.44
12 CL Clay 6.4 6.5 45.5 17.98 8.77 21.25 26.95
13 SC Sand 2.0 2.0 50 17.59 8.40 23.01 20.58

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4. Corrosion ratio
Based on “DNVRP-0416: Corrosion protection for wind turbine”, set below values for calculation.
Outside 1.2mm, Inside 0.6mm, Total 1.8mm

Outside: CA=0.4mm/year *(Construction 3 years + service life 20 years) – (duration of corrosion paint 20years)
Inside: CA=0.2mm/year *(Construction 3 years + service life 20 years) – (duration of corrosion paint 20years)

5. Fatigue limit
Based on ‘DNVGL-RP-C203: Fatigue design of offshore steel structures, August 2005’ fatigue limit is as below.

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6. Minimum thickness of Steel Pipe Pile

Based on ‘DNVGL-ST-0126: Support structures for wind turbines’ we set minimum thickness as below.

Upper pile Lower pile

Material Grade SKY490 SKY400
Yield point fy (N/mm2) 315 235
ε 0.864 1.000
Diameter d (mm) 1600 1600
Minimum Thickness tp (mm) 23.8 17.8

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7. Allowable material strength

Based on JIS A5525:2009 and DNVGL-ST-0126, set as below.

⇒ Allowable pile body compression/tensile strength Fy=315N/mm2 / 1.10 = 286.36N/mm2

8. Reference standards
1) JIS A5525 Steel Pipe Piles
2) DNV Classification Notes 30.4: Foundations, February 1992
3) 風力発電設備支持構造設計指針・同解説,土木学会,2010
(Guidelines for supporting structures for wind power generation equipment and commentary, JSCE, 2010)
4) 道路橋示方書・同解説 下部構造編,2017, 日本道路協会
(Highway bridge design specification, substructure, 2017, Japan Road Association)
5) DNVGL-ST-0126: Support structures for wind turbines, April 2016
6) DNVGL-RP-C203: Fatigue design of offshore steel structures, August 2005
7) DNVGL-RP-0416: Corrosion protection for wind turbines, March 2016
8) TCVN5747,1993: Soil classifications for civil engineering

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Ⅱ.Design result
1. Result
Foundation size: φ15,900mm x Thickness 4,000mm
Pile size: Upper pile D1600 x t25mm x L31.8m (SKK490)
Lower pile D1600 x t18mm x L36.9m (SKK400) , Splicing at factory (L=68.7m/pile)
Total Pile number is 8 pcs/pier

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(Calculation result table)

Maximum value of
Item Unit Load Allowable value Verify
acting force
Foundation pile compression
kN/pile Extreme 5,591 16,180 OK
bearing capacity
Foundation pile uplift bearing
kN/pile Extreme 3,936 6,756 OK
capacity
2
Pile body compression stress N/mm Extreme 120.1 286.3 OK
Fatigue stress N/mm2 Fatigue 37.7 52.63 OK
Foundation top flange face
rad Extreme 1.87/1000 4.0/1000 OK
angle
Horizontal Stiffness of Quasi-
N/m 3.57 x 108 3.03 x 108 OK
foudation permanent
Rotational Stifness of Quasi-
Nm/rad 7.33 x 1010 6.60 x 1010 OK
foundation permanent

2. Calculation of pile bearing capacity

Based on DNV Classification Notes No.304 Foundations February 1992
[Foundation pile compression bearing capacity (at Extreme loads)]
Skin Friction Tip Resistance Bearing Safety factor Design bearing
(kN) (kN) capacity (kN) capacity (kN)
D1600 10,574 9,651 20,225 1.25 16,180
[Foundation pile uplift bearing capacity (Extreme)]
Skin Friction Tip Resistance Bearing Safety factor Design bearing
(kN) (kN) capacity (kN) capacity (kN)
D1600 8,445 - 8,445 1.25 6,756

3. Verify rotational stiffness and horizontal stiffness (at Quasi-permanent loads)

Acting force Deformation Calculated stiffness
Horizontal stiffness (Khor) Fxy=714.27kN 2.00mm 3.57 x 108N/m
Rotational stiffness (Krot) Mxy=77,790kNm 0.00106rad 7.33 x 1010Nm/rad

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4. Estimated steel volume for single pier

Size Unit Pile weight Pile Number Total pile weight
weight
Upper D1600 x t25mm 971 kg/m 30.88 ton 8 pcs 247.02
Pile x 31.8m
Lower D1600 x t18mm 702 kg/m 25.9 ton 8 pcs 207.23
Pile x 36.9m
56.78 ton 8 pcs 454.25ton
*Above calculation excludes accessories weight such as lifting lugs, tip band.

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Calculation sheet

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