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Prefabricated Solutions for New Power Stations
The energy transition is in full swing. Throughout the Netherlands, high- and medium-voltage substations are being expanded, modernized, or built from scratch to meet the growing demand for electricity. Did you know that a large portion of these power stations are constructed using prefabricated components? While standardization is certainly desirable, practice often requires customized solutions.
For Van Dijk Beton, the energy transition is an important market. In recent years, the company has supplied precast elements for a large number of projects, including those for TenneT and Alliander. These range from new 380 kV substations in Beverwijk, Zevenhuizen, Tilburg, and Maasbracht to 150 kV projects in locations such as Venray, Graatheide, Lutterade, and Boldershoek near Spijkenisse. “Our strength lies in our broad range of products,‘ says Director Henk Schaap. ”We manufacture prefabricated cable trays, sheet pile walls, foundation elements, substation portals, and industrial walls for GIS and MS buildings, among other things. In addition, we supply heavy-duty foundation structures, such as BRP footings and the so-called Mobriq beams, which have now been used on multiple projects.“
One of Van Dijk Beton’s largest ongoing projects is located in Maasbracht, where a new 380 kV substation is being built. “We’re producing approximately 2,700 footings and columns for this project,” says Henk. “These include a variety of foundation elements, ranging from basic footings to large foundation slabs on which multiple columns are placed. Some of the precast elements reach impressive dimensions of 3 meters long, 1.5 meters high, and 1 meter wide.”
We also supply special structures for other projects. “For example, we’re manufacturing exceptionally heavy diaphragm walls for the Simonshaven station. Some of these are 35 centimeters thick, 2.5 meters wide, and 8 meters high, weighing 17.5 metric tons each. In addition, we produce walls that are no less than 12 meters high and weigh 35 metric tons. It’s noteworthy that these elements are installed vertically on site, whereas concrete panel walls are typically installed horizontally.”
To make such projects possible, Van Dijk Beton invested, among other things, in new tilting tables for the production of large precast wall elements. This enables the company to meet the ever-increasing and more complex demand from the energy sector.
Although the industry is actively seeking standardization, putting it into practice has proven challenging, says Henk. “Differences in design specifications, contractor preferences, and regional standards mean that many projects still require specific solutions. As a result, details such as drainage, connections, and the positioning of the covers often vary from project to project.” According to Henk, there is still a lot of potential here. “With far-reaching standardization, prefabricated elements could be produced more quickly and efficiently. In theory, we could then use standard molds. But that’s still a bridge too far for now, because every station has its own technical and spatial challenges.”
Even when a design goes off the beaten path, Van Dijk Beton comes up with a solution. “Whether it’s aesthetic retaining walls with fluting, special three-compartment cable ducts in a single precast element, or 16-meter-long foundation beams: the energy transition calls for solutions that are both technically feasible and practical to implement,” says Henk. “With a complete package of precast concrete solutions, we’re playing an increasingly important role in this.”
