Cooling tower construction

Cooling tower construction
Expertise and experience
Power Station
Construction

Power Station
Construction
Visions and Actions –
Shaping the Future Together
With our expertise, we are successfully represented in all
sectors of the construction industry, where we are
renowned for our innovative building techniques and
adherence to schedules.
Our portfolio extends from turnkey industrial buildings,
innovative power stations, spectacular cooling towers,
residential and office buildings, and imposing
bridges to modern hydraulic engineering and infrastructure
projects.
We supplement classical construction activities with
numerous services, such as planning, structural analysis,
facility management, those of our Mechanical Engineering
Department (MTA) and the Competence Centre for
Construction Material and Concrete Technology.
A high level of quality in the realisation of demanding
construction projects is guaranteed by our integrated and
certified management system. Active membership in the
registered association “Ethik Management der Bauwirtschaft”
(ethical management in the construction
industry) demonstrates ALPINE‘s value-based approach to
management. With our comprehensive safety criteria
we aim for the highest standards of health and safety in all
areas of construction activity. As a responsible company
the protection of the environment is an integral part of our
corporate culture and an essential aspect of daily activities.
Our strength lies in our flexibility in implementing complex
requirements. This applies to projects of all sizes. Every day
our employees take the great responsibility of successfully
realising your construction projects.

ADDITIONAL REFERENCE PROJECTS
Grafenrheinfeld
> Fuel element container storage
> Cooling tower refurbishment
Essenbach
> Emergency diesel-power building
> Blowdown cooler
Knapsack
> Cell cooler
Hamm
> Coal-fired power plant
Datteln
> Datteln 4 power station
Hamm-Uentrop
> Gas and thermal power station
Eemshaven (Netherlands)
> Coal-fired power station
Hybrid cooling tower,
Hamburg-Moorburg / DE
Constr. period: 11.2010 – 08.2012
Order value: approx. € 36 million *
04
Fan assisted natural
draught cooling tower,
Karlsruhe / DE
Constr. period: 05.2009 – 05.2011
Order value: approx. € 19 million *
05
Natural draught cooling
towers, Neurath / DE
Constr. period: 01.2006 – 12.2008
Order value: approx. € 38 million *
06
Mechanical draught
cooling tower, Essenbach-
Landshut / DE
Constr. period: 07.2008 – 03.2009
07
* Total for construction and planning services
Cooling innovations
With the development of special construction methods, ALPINE has a
clear technological advantage in all types of cooling tower. ALPINE can
produce references ranging from hybrid cooling towers, fan assisted
natural draught cooling tower and natural draught cooling towers to the
latest generation of cell coolers.
A 20 - 40% reduction in the construction period thanks to ALPINE’s
expertise and professionalism in areas extending from planning and work
preparation to construction, in conjunction with increased occupational
safety, distinguishes our innovative special solutions.
InnovatIve clImbIng scaffold
Climbing operations take place in cycles corresponding to the concreting
operations in rings approx. 120 cm high. Tower climbing is automated by
means of hydraulic cylinders, whereby the telescopic working platforms
adapt to the hyperbolic shape of the cooling tower.
For its work in developing the climbing scaffold, ALPINE has been distinguished
with such prizes as the FCC Innovation Award.
acId-resIstant hIgh-performance concrete
Depending on requirements, a special high-performance concrete - developed
and optimised by ALPINE and featuring a new mixing technique
- is used, rendering costly internal coating of the cooling tower shells
superfluous. This provides a time saving of six months in construction.
Because of this concrete, there is no need for recoating the inside of the
cooling tower every 15 years, a process that would otherwise require a
six month operational shutdown.
Naturally, the special solutions developed by ALPINE also allow coating
systems to be employed on request.
everythIng from a sIngle source
ALPINE handles the entire project management of challenging cooling
tower projects. Our specialists in the technical departments of
the Engineering Office, Work Preparation, the Competence Centre for
Construction Material and Concrete Technology, Surveying, the Mechanical
Engineering Department and, not least, construction itself ensure
successful completion of building works in accordance with the highest
quality standards and to the total satisfaction of our customers.
Additional information and further
reference projects can be found on
our website.
www.alpine-bau.de

04
Power Station Construction
Hybrid cooling tower
Hamburg-Moorburg
A coal-fired power plant is being built
in Moorburg with a hybrid cooling
tower. Special requirements for the
overall height and block operation of
the cooling tower represented the
major challenges in the planning phase.
Together with our consortium partner
Hamon Thermal Germany GmbH, we
implemented the customer’s requirements
during the planning phase.
During construction, the building
technique developed by ALPINE featuring
the ALPINE scaffolding proved to be
the ideal solution, particularly due to
the very cramped working conditions.
For the formation of the openings
in the wet and dry part, ALPINE has
developed technical solutions for
operational optimisation and observing
general safety conditions, for which
a patent is pending to protect the
company’s intellectual property rights.
ALPINE develops cost-effective construction
methods that ensure completion deadlines.
FEATURES
Optimisation of pile foundations
36 round fan openings approx. 8.70 m in diameter
36 rectangular openings (approx. 9.50 x 8.75 m) in the dry part of the
cooling tower shell
HYBRID COOLING TOWER
HAMBURG / GERMANY
Planning and construction output:
earthworks, special foundations, steel
construction and reinforced concrete
work
Height: 60 m
Constr. period: 11.2010 – 08.2012
Order value: approx. € 36 million
(construction)

Fan assisted natural draught
cooling tower Karlsruhe
A circular fan assisted natural draught
cooling tower was erected at the RDK8
coal-fired power station in Karlsruhe.
The unique construction was planned
and built with the ALPINE climbing
scaffold and the associated shell
system. Development of the building
enabled the fulfilment of the strict
tolerance requirements in conjunction
with the very tight construction period.
The so-called “combi-structure” was
erected in the centre of the cooling
tower. This facilitates switching between
different operating modes from
through-flow to outflow operation.
ALPINE finds cost-effective solutions for
its clients.
FEATURES
Foundations with vibro-compaction columns
28 round openings in the cooling tower shell with a diameter of approx. 7.20 m
Combi-structure for switching between different operating modes
Planning in collaboration with Hamon Thermal Germany GmbH
Power Station Construction
FAN ASSISTED NATURAL
DRAUGHT COOLING TOWER
KARLSRUHE / GERMANY
Planning and construction output:
earthworks, special foundations, steel
construction and reinforced concrete
work
Height: 80 m
Constr. period: 05.2009 – 05.2011
Order value: approx. € 19 million
(construction)
05

06
Power Station Construction
Natural draught cooling
towers Neurath
Two cooling towers were erected for
the new lignite-optimised power plants
F and G in Grevenbroich, in the immediate
vicinity of Neurath power station.
Their state-of-the-art design represented
a completely new technical
challenge. The climbing scaffold
developed especially for this purpose
adapts automatically to the construction
progress and shape of the cooling
tower. With the development and
optimisation of a special acid-resistant,
high-performance concrete, ALPINE
demonstrated its technological
expertise in modern power station
construction.
ALPINE innovations shorten the construction
period and increase the level of safety for
workers.
FEATURES
Acid-resistant concrete of cooling tower shells and trickle grates
Use of the ALPINE scaffolding for creating cooling tower shells
NAT. DRAUGHT COOLING TOWERS
NEURATH / GERMANY
Planning and construction output:
erthworks, special foundations, steel
construction and reinforced concrete
work
Natural-draught cooling towers:
each 172 m high
Shell surface area: 80,000 m² each
Constr. period: 01.2006 – 12.2008
Order value: approx. € 38 million
(construction)

Mechanical draught cooling
tower Isar nuclear power
station
In order to increase the cooling capacity,
a new cell and blowdown cooler
was built at the Isar nuclear power
station in the immediate vicinity of the
existing cell cooler. The design selected
by ALPINE, featuring prefabricated
reinforced concrete units and semi-
finished parts, allowed fulfilment of
the exacting requirements made of
the concrete surfaces in the cooling
cells. Building work was completed
successfully not least due to the good,
close collaboration between planning,
construction and the client.
ALPINE complete solutions for all
requirements from approval planning to
commissioning from a single source.
FEATURES
Construction of a cell and blowdown cooler under extremely strict
time constraints
Very short planning phase prior to start of construction
General nuclear legal conditions
Power Station Construction
MECHANICAL DRAUGHT COOLING
TOWER
ESSENBACH-LANDSHUT / DE
Planning and construction output:
earthworks, special foundations, steel
construction and reinforced concrete
work
Constr. period: 07.2008 – 03.2009
07

ALPINE Bau Deutschland AG · Industrial & Power Station Construction
Kronenburgallee 1 · 44141 Dortmund · Germany · Telephone +49 231 5413-0 · Fax -632
powerstation@alpine-bau.de · www.alpine-bau.de
Subject to changes, printing errors and/or typographical errors. Last updated: 01.2012 / I