Pilot-Biogas plant consisting of prefabricated units

Construction of a biogas tank built of prefabricated reinforced concrete elements, erected and operated at an existing biogas plant in Bruck an der Leitha. The precast concrete technology promised a lot of advantages but also posed a lot of questions that had to be solved. These problems considered especially the sealing method and the general construction with precast concrete elements.

Short Description

Status

ongoing

Summary

As efforts in recent times show, the expansion task provided by the EU Renewable Energy Directive of raising the percentage of Renewables in our energy mix, is a hard achievable goal. Thus, the Kirchdorfer Industries Group decided to focus parts of their research on biogas tanks made of precast reinforced concrete elements to make a contribution to the mentioned issue.

The main advantages with that technology are:

The developed system provides reduction of construction time down to one month for a tank regardless of which size
A higher chemical and biological resistance of the concrete without any coating by using a special hydraulic binder named SLAGSTAR
The preferred application of a central agitator because of a hard-top roof also made of precast reinforced concrete elements
A high processing- and material quality ensured by the precast fabrication technology
Reduced planning times with standard tanks from 2000 - 4000 m³ capacity

In cooperation with Biogas GmbH in Bruck an der Leitha, Wopfinger Baustoffindustrie and the Technical University of Vienna, a prototype with a volumetric capacity of 3000m³ was planned and erected. The patented technical design is leant on the tubbing technology, well known in tunnel construction. 22 side wall elements, each measured 11,6m in height, 2,7m in width, 18cm in thickness and 16t in weight, were assembled on a prepared foundation plate. The roof is built of 13 pre-stressed double T-beam disk carriers. Sealing systems with frames made of EPDM seal tapes (as used for tubbings), already clamped on the side wall elements in the factory, as well as subsequently applied sealing systems had been verified during the project. Ensuring stability according to statics, 27 external unbounded pre-stressing wires were applied with 80 tons of tension force each.

Providing that information, a lot of problems and perfidies had to be solved in advance. Especially the pre-stressing process in combination with the sealing system encountered unforeseeable issues, but eventually the claimed task of absolute water and gas tightness was fullfilled.

Project Partners

Project management

DI Alexander Barnas
MABA Fertigteilindustrie GmbH

Project or cooperation partner

BM Ing. Eduard Leichtfried
BAUMIT Wopfinger Baustoffindustrie GmbH
DI Gerhard Danzinger
BIOGAS GmbH Bruck an der Leitha
Dipl.-Ing. Dr.techn. Sinan Korjenic, Dr. Friedrich Loibnegger, DI Harald König, DI Dr. Karl Deix
TECHNISCHE UNIVERSITÄT WIEN - Institut für Hochbau
Dr. Franz Benjamin Schügerl
UNIVERSITÄT WIEN - Institut für Risikoforschung

Contact Address

DI Alexander Barnas
MABA
Industriestraße 28
2601 Sollenau
Tel.: +43 (2628) 410-300
E-Mail: alexander.barnas@maba.at
Internet: www.maba.at