In a world in the midst of energy transition, transformer stations play a major role. With gas playing an increasingly minor role, the importance of electricity is increasing. The many transformer stations scattered across districts and industrial estates are vital elements in the chain from energy producer to user. Alfen has specialised in this field for more than 60 years. To produce the prefab transformer stations, the company uses moulds. Three new moulds from Hendriks precon were recently added.
In recent years, Alfen produced and supplied many tens of thousands of transformer stations to grid operators, (industrial) companies and the horticultural sector. This long-term success is partly due to continuous innovation and the use of the latest technology. This makes Alfen transformer substations suitable for all situations and types of users. When it comes to the construction of the substations themselves, the company has relied for many years on Hendriks precon, which supplies the moulds used to manufacture the concrete substations. A recent addition concerns the mould for a new type of compact station.
Martin Pieterson of Alfen commented, "The new mould presented the necessary challenges and required engineering expertise from Hendriks precon. The size of the transformer stations made with this mould is modest. But at the same time, a high degree of flexibility is required on the inside because the interior space is divided into three rooms that can be in different configurations. We met these challenges together with Hendriks precon. We have been working with them for many years and were therefore the obvious partner for this project."
The mould is slightly elevated from the floor and thereby consists of a core with movable outer walls. "The transformer station is finished on the outside with vertical cannelures. Besides being aesthetically pleasing, the cannellas also fit within the anti-posting policy of many companies and municipalities," says Martin Pieterson.
Noteworthy is the design of the inner part that comprises three separate rooms, so that transformer and low- and medium-voltage equipment are separated. Nevertheless, the inner and outer walls of the transformer station are produced as a monolith. "To this end, the core of the mould consists of three parts formed by notches. By placing steel recesses, different versions of the station can thus be produced with one mould."
As the core and outer walls are set up slightly elevated, the core can be moved downwards using hydraulic cylinders at the bottom. "All three core parts can thereby be unloaded downwards separately from each other before the station as a whole is pushed upwards. Special air vents in the core prevent vacuum from forming in the process." The combination of three separate hydraulic units for the inner core in a modest area made special demands on Hendriks precon's inventiveness. "One of the inner cores can also be driven away at an angle to make the core easily accessible for cleaning, maintenance and fitting pour-in parts."
Martin Pieterson continues: "The outer walls of the mould are on wheels, so they can be driven open and closed with hydraulic cylinders. All walls have a shaft that protrudes through the perpendicular wall when closed. The outer partition is then automatically secured using hydraulic wedges, of which there are a total of 12 on the mould. This saves us a lot of labour. As the outer walls are equipped with a working platform on all four sides, the pouring work can be carried out safely and reliably." The roof is supplied with the station as a loose element. All stations are installed fully equipped in the field, but the loose roof design allows a component to be exchanged in the field via the roof if necessary.
When asked about the cooperation with Hendriks precon, Martin Pieterson answers enthusiastically: "Working with Hendriks precon works well. Making these moulds work well requires a high degree of precision and a lot of engineering expertise. Hendriks precon masters that like no other. Once again, they managed to develop a fine solution to still accommodate the large amount of hydraulics needed to unload the core in the core parts. A solid challenge and an achievement of stature."
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