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08.12: Mega composite columns in plant construction

Plant structures in industrial facilities are often very large and can reach a height of up to 150m. Although composite steel‐concrete structures can be found worldwide in many areas of construction, the large towers in plant structures are still commonly built as truss or framework structures of pure steel or of concrete construction. As an innovative alternative, the columns – the most important elements of the structure – can be made as a steel‐concrete mega composite construction. In several pilot studies and two design projects these new column types were developed for the application in plant constructions as a boiler support structure for steam power plants and as a preheater tower for cement plants. In a first pilot project, composite columns measuring approximately 2m × 2m cross section size and with a height of almost 100m were successfully executed. Within this paper two different types of these “Mega Composite Columns” are explained and compared in detail from a static, structural and manufacturing point of view. Moreover, the most significant features in the design and construction of these “Mega Composite Columns” in plant construction are pointed out herein. Especially the design of the main joints (columns‐beams‐diagonals) is essential in such composite structural elements for economic reasons; therefore different examples of these main connections are presented and discussed. Furthermore, new innovative concepts for optimizations of these details are presented in order to enhance the future profitability of this construction.