Solution Overview
Onshore wind turbine foundations demand specialized grouting solutions for both internal post-tensioned anchorage ducts and tower baseplate connections. Our solution addresses both applications with high-strength, non-shrink cementitious grouts formulated for extreme durability. These materials deliver excellent fluidity, volume stability, and fatigue resistance, ensuring secure load transfer from tower to foundation.
ZRETE’s Kuaizhuang Assembled Grout for Wind Power fills and protects internal tendon ducts, while CBGM Onshore High-Strength Non-Shrink Grout beds the turbine baseplate and anchor bolts. Both grouts meet international performance standards (ISO, ASTM) for strength, stability, and corrosion protection, providing a long-lasting foundation in demanding wind farm conditions.
In some wind turbine foundation designs (including hybrid concrete towers or foundations with anchor cages), post-tensioned steel tendons or bolts are installed in ducts that run through the concrete. After tensioning these tendons, the ducts are pressure-grouted with a cementitious material to lock in the prestress and protect the steel from corrosion.
Engineering Challenges:
Grouting tendon ducts can be demanding because the ducts may be long, curved, or even vertical (for example, extending up an 80+ meter concrete tower). The grout must be highly fluid and pumpable to travel long distances and fill all voids without trapping air. It should remain stable under pressure, with no bleeding or segregation, even when pumped upward tens of meters. Once in place, the grout must harden without shrinking, so that it bonds to the tendon and duct walls, ensuring complete encapsulation.
International standards such as ISO 14824 / EN 447 require nearly zero bleeding (<2%) and slight positive expansion of the grout to eliminate shrinkage voids. The hardened grout should exceed 30 MPa at 28 days and remain chloride-free to avoid steel corrosion.
Solution Approach:
To meet these needs, Kuaizhuang Assembled Grout for Wind Power is formulated as a highly fluid, anti-bleed cementitious grout. It can be pumped through narrow ducts while maintaining a homogeneous mix. The grout exhibits controlled expansion to ensure a tight, void-free fill that grips tendons and duct walls, ensuring long-term protection. With a chloride-free, non-corrosive composition, it preserves steel integrity and exceeds ISO/EN requirements for non-shrink duct grouts.
At the interface between the steel tower and its concrete foundation, a critical grouted connection must safely transfer massive static and dynamic loads. The baseplate grout forms the load-transfer layer, evenly distributing stresses and preventing movement.
Engineering Challenges:
The baseplate grout must endure heavy compression, bending, and cyclic fatigue over decades. Ordinary materials can crack or settle, risking uneven load transfer. Therefore, the grout requires ultra-high compressive strength (80–130 MPa), high modulus, and non-shrink stability. Industry standards like ASTM C1107 specify slight expansion for tight contact. Fast strength gain (e.g., >60 MPa in 24 hours) allows early anchor bolt tensioning and turbine erection. The material must also be durable in extreme weather, resistant to freeze-thaw, and chloride-free.
Solution Approach:
CBGM Onshore High-Strength Non-Shrink Grout delivers compressive strength above 120 MPa with micro-expansive, non-shrink behavior. It develops >40 MPa in 24 hours, permitting early bolt tightening. CBGM maintains high flowability and self-compaction, ensuring a void-free fill under the baseplate. With fatigue-tested formulations, it withstands millions of load cycles and retains performance under severe dynamic stresses. It is non-corrosive, frost-resistant, and moisture-stable, meeting both ISO and ASTM performance standards for wind turbine foundations.
High Compressive Strength: ≥100 MPa at 28 days for structural safety
Volume Stability: Controlled micro-expansion, compliant with ISO 14824 / ASTM C1107
Fluidity & Pumpability: Stable, non-bleeding, cohesive flow for long-distance pumping
Fatigue Resistance: Capable of enduring 20+ years of cyclic loading without micro-cracking
Bond Strength: High adhesion to steel and concrete, void-free encapsulation
Corrosion Protection: Chloride-free, non-metallic, high-pH cementitious matrix
Environmental Durability: Freeze–thaw and sulfate resistance for exposed climates
Kuaizhuang Assembled Grout for Wind Power
High-fluidity duct grout for post-tensioned anchorage systems
Zero bleeding, controlled expansion, full tendon encapsulation
Chloride-free and non-corrosive, protects prestressing steel
CBGM Onshore High-Strength Non-Shrink Grout
Ultra-high strength (80–130 MPa) for baseplate and anchor bolts
Shrinkage-compensated, micro-expansive performance
High fatigue resistance and rapid early strength (>40 MPa/24 h)
Frost- and corrosion-resistant for all onshore environments
Baseplate & Anchor Bolt Grouting Solution
The interface between a wind turbine’s steel tower and its concrete foundation is critical for transferring dynamic and static loads safely. The baseplate and anchor bolts must be securely grouted with a high-performance, precision material capable of withstanding high compressive stress and long-term fatigue.
ZRETE’s CBGM Onshore High-Strength Non-Shrink Grout is engineered specifically for wind turbine foundation applications. This cementitious grout combines ultra-high compressive strength (typically 80–130 MPa at 28 days) with controlled micro-expansion, ensuring complete contact with both steel and concrete surfaces. Its non-shrink formulation eliminates voids or gaps beneath baseplates, guaranteeing consistent load transfer and alignment stability.
CBGM grout demonstrates rapid early strength gain (>40 MPa within 24 hours), enabling faster commissioning and bolt tensioning. It remains highly flowable and pumpable, suitable for large-diameter baseplates where the material must flow across several meters without segregation or bleeding. The hardened grout layer offers exceptional fatigue resistance, maintaining structural performance under millions of cyclic loads generated by turbine operation.
Designed for long-term durability, CBGM grout is chloride-free, non-metallic, and resistant to frost and moisture. It retains its integrity under temperature variations and environmental exposure, making it ideal for harsh onshore and coastal sites. By using CBGM Onshore Grout, contractors can ensure that every turbine base achieves a permanent, fatigue-resistant connection that matches international ISO and ASTM standards for non-shrink, high-strength precision grouts.
Post-Tension Anchorage Duct Grouting Solution
Post-tensioned anchorage systems in wind turbine foundations use steel tendons installed inside ducts to enhance foundation performance and minimize cracking. After tensioning, these ducts must be fully grouted to protect the tendons from corrosion and to transfer stresses effectively.
ZRETE’s Kuaizhuang Assembled Grout for Wind Power meets the demanding requirements of this application. The grout is highly pumpable and stable, allowing long-distance or vertical injection without segregation. It exhibits zero bleeding and micro-expansion, ensuring complete filling and intimate contact with the tendon and duct wall. This eliminates voids and guarantees full encapsulation of steel strands, preventing air pockets and potential corrosion zones.
The grout achieves high early and final compressive strength, with 28-day strength typically exceeding 30 MPa, providing mechanical integrity and long-term bonding between steel and concrete. Its chloride-free and non-corrosive composition ensures complete protection of post-tensioning steel, while its low permeability prevents ingress of moisture or aggressive ions.
ZRETE’s duct grouting system aligns with international standards such as ISO 14824 and ASTM C1107 for non-shrink cementitious grouts, ensuring compliance with performance benchmarks for fluidity, volume stability, and corrosion resistance. With Kuaizhuang Assembled Grout, contractors can achieve reliable, void-free post-tension anchorage protection — securing both structural safety and long-term durability of onshore wind turbine foundations.
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