On-site 3D Concrete Printing for Next-Generation Low-Cost Wind Plants

Advancing on-site 3D concrete printed turbine towers to enable tall wind development.

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Tech Partner

RCAM Technologies, dba Sperra

Recipient

Irvine, CA

Recipient Location

37th

Senate District

73rd

Assembly District

beenhere

$2,940,269

Amount Spent

closed

Completed

Project Status

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Project Result

All project activities have been completed. The team performed large-scale laboratory testing of 3D printed concrete tower sections, evaluating how they perform under simulated fatigue and earthquake conditions for a 7.5-MW reference turbine. An outdoor on-site printing demonstration showed that the approach is practical and feasible for field deployment. The team also completed lifecycle cost and environmental analyses, identifying ways to further reduce both embodied carbon and capital costs compared with conventional steel towers. In addition, the project delivered feasibility assessments for offshore anchors and subsea energy storage systems, helping to expand future commercialization options for on-site 3D concrete manufacturing in California.

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The Issue

Wind energy, both onshore and offshore, can play a significant role in helping California reach its ambitious renewable energy mandates. As required by Senate Bill 525, the California Energy Commission adopted planning goals of 2 to 5 gigawatts of offshore wind energy by 2030 and 25 GW gigawatts by 2045. On-site 3D printed concrete can advance California’s renewable energy objectives by streamlining wind plant construction. This on-site additive manufacturing model can mitigate the limitations associated with transporting large steel wind turbine towers.

Project Innovation

Project Goals

Advance manufacturing methods to enable on-site 3D printing concrete towers taller than1 20 meters.

Reduce the environmental lifecycle impacts of 3D printed concrete manufacturing.

Expand California's R&D capabilities and workforce potential for in-state manufacturing.

Project Benefits

3D concrete printed (3DCP) towers will reduce tower capital costs by up to approximately 50% compared to 140-m steel tower for a 7.5-MW next generation turbine. RCAM's technology is faster and safer than conventional concrete construction methods, while providing new transformative design possibilities that reduce cost and energy consumed by using less concrete than conventional construction and by eliminating concrete forms. The highly mobile 3DCP equipment and California's existing concrete supply chain can cost-effectively produce towers and foundations on-site in manufacturing lots of any size needed for California wind plants. The scope included design, fabrication, pilot testing and demonstration of tower sections at up to 1:2 scale in laboratory and outdoor environments.

Consumer Appeal

3D printed concrete manufacturing results in taller wind turbines, which can significantly reduce the number of turbines in a wind energy area while still reaching plant capacity.

Affordability

This 3D printed concrete technology aims to enable on-site construction of a hybrid 140-meter wind turbine tower at half the cost of conventional steel tower for a 7.5 MW next generation turbine.

Economic Development

This 3D printed concrete technology aims to enable on-site construction of a hybrid 140-meter wind turbine tower at half the cost of conventional steel tower for a 7.5 MW next generation turbine.

Environmental Sustainability

Wind deployments avoid substantial emissions of greenhouse gases compared to fossil fuel generated electricity. Wind generated electricity emits up to 120 times less carbon dioxide than natural gas generated electricity.