JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 45

All-composite lighthouse

Fig. 3: The GFRP stairs

Fig. 4: The ready-to-use lighthouse

system using a low-cost aluminium mould and a highly
specific labour-free resin infusion process was developed
by the team to manufacture
the carbon and glass fibre
hybrid bracing elements. An
easy-to-impregnate, epoxycompatible glass fibre from
Owens Corning providing
faster pulling speed and better chemical resistance was
used to manufacture the
GFRP tubes.
The third challenge was
to design and develop
lightweight GFRP floors
meeting the architectural
requirement
of
not
exceeding 20cm thickness

in addition to the structural
and chemical resistance
requirements.

otropic, fast-curing adhesive
developed by Huntsman was
selected.

Cost, time, dimensional tolerance, surface finish and
ease of moulding were major
concerns here. Since only 5
floors were to be made within a period of 10 days, the
cost and time investment
in the mould and production time had to be low. A
low-cost wood mould was
designed and developed in
order to meet the dimensional tolerance, surface finish and ease of demoulding
requirements. A fast-curing,
low-viscosity resin with a
long pot life and low exotherm from Huntsman was
selected for the resin infusion process strategy.

Assembly, transportation erties of low weight, high
strength-to-weight
ratio,
and installation

The fourth challenge was to
design and develop specific stairs that had to be slipfree, lightweight (<25kg),
chemically and mechanically
resistant while meeting the
architectural requirements
(not exceeding 20cm thickness). Conventional materials such as concrete and
steel could not meet these
requirements, so GFRP was
selected to manufacture the
stairs (Figure 3) using an
RTM process.
The fifth challenge was to design the structural bonding
system. Chemically-resistant,
smooth-finish
metal-free
joints had to be designed and
developed.
All the components - CFRP
tubes, GFRP tubes, carbon
and glass hybrid stiffeners,
GFRP floors, and GFRP stairs
¬- then had to be joined.
Metal fasteners were avoided
for weight and aesthetics reasons and a low-cost, high-thix-

Once all the components
were manufactured, a special
protective coating developed
by Hempel for UV and marine
environments was applied.
The main structure was
assembled at one of Acciona
Infrastructures's
facilities
located on the outskirts
of Madrid. The structure
was quickly and easily
transported from Madrid
to the port of Valencia on a
truck. The installation was
achieved in less than half a
day using standard cranes
(Figures 4 and 5). All this
was made possible by the low
weight of composites. A final
test was performed before
putting the lighthouse into
operation in order to ensure
that it met the load and wind
requirements.

Value creation, benefits
and market
The advantages of this solution include fast and easy
installation on sites with difficult accessibility, fast manufacturing, reduced maintenance costs, longer life, wide

design capabilities and improved aesthetics.
Due to their inherent prop-

higher resistance and low
maintenance, the use of
composites in the construction and civil engineering
industries presents many
opportunities. The all-composite lighthouse for highly
aggressive environments is
a perfect example of such
an opportunity. This lighthouse proved that a vertical
structure meeting strict architectural, strength and service life requirements could
be build using composites,
opening up new markets for
such applications in rapidly
growing countries or countries with extremely aggressive environments.
The lighthouse project was
a collaborative process involving teams of composite
specialists from Huntsman,
Owens Corning, Saertex,
DOW chemicals, Autoridad
Portuaria
de
Valencia,
Siegrist & Moreno, Aimplas
and Hempel.
More information:
www.acciona.com

Fig. 5: The lighthouse in operation

No108 October 2016

/ jec composites magazine

45


http://www.acciona.com

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #108 - October 2016

Cover
Edito
Opinion: BOI Thaïlande
Contents
NEWS
In brief
Agenda
JEC Conferences 2017
BUSINESS
Merging
Basalt
MANUFACTURING
Biocomposite
Green Materials
3D Printing
Feature Wind energy RECORD BEATING INDUSTRY
Resin
Performance
Recycling
Recycling
Offshore
Process
Design
Market
SOLUTIONS
Marine
Infrastuctures
Construction
Pavilion
In the world
TECHNOLOGY
Simulation
Repair
Index
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - BckCovAd
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Cover
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 2
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Edito
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Opinion: BOI Thaïlande
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 5
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Contents
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 7
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - In brief
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 9
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Ad1
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Ad2
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Agenda
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - JEC Conferences 2017
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 12
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Merging
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 14
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Basalt
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 16
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 17
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 18
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Biocomposite
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 20
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 21
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Green Materials
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 23
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 3D Printing
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 25
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 26
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Resin
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 28
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 29
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Performance
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Recycling
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 32
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Recycling
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Offshore
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Process
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 36
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Design
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Market
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 39
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 40
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Marine
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 42
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 43
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Infrastuctures
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 45
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Construction
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 47
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Pavilion
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 49
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - In the world
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 51
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Simulation
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 53
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 54
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Repair
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 56
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 57
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - Index
JEC COMPOSITES MAGAZINE - Issue #108 - October 2016 - 59
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