Transformer stations play a major role in a world that is undergoing an energy transition. As gas becomes less important, the importance of electricity is increasing. The many transformer stations located throughout neighbourhoods and industrial estates are vital elements in the chain from energy producer to consumer. Alfen has specialised in this field for more than 60 years. The company uses moulds to produce prefabricated transformer stations. Three new moulds from Hendriks precon were recently added to the range.
In recent years, Alfen has produced and delivered tens of thousands of transformer stations to network 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 stations suitable for all situations and types of users. When it comes to the construction of the stations themselves, the company has relied on Hendriks Precon for many years to supply the moulds used to manufacture the concrete stations. A recent addition is the mould for a new type of compact station.
Martin Pieterson of Alfen comments: “The new mould presented a number of challenges and required the necessary engineering expertise from Hendriks precon. The size of the transformer stations made using this mould is modest. At the same time, however, a high degree of flexibility is required on the inside because the interior space is divided into three rooms that can be configured in different ways. We took on 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 raised off the floor and consists of a core with movable outer walls. "The transformer station has vertical fluting on the outside. In addition to their attractive appearance, the fluting also complies with the anti-advertising policies of many companies and municipalities," says Martin Pieterson.
The design of the inner section is remarkable, comprising three separate spaces so that the transformer and low- and medium-voltage equipment are separated from each other. Nevertheless, the inner and outer walls of the transformer station are produced as a single piece. "To achieve this, the core of the mould consists of three parts formed by recesses. By inserting steel cut-outs, different versions of the station can be produced using a single mould."
Because the core and outer walls are slightly raised, the core can be lowered using hydraulic cylinders at the bottom. "All three core sections can be lowered separately before the station is pushed up as a whole. Special air vents in the core prevent a vacuum from forming." The combination of three separate hydraulic units for the inner core on a modest surface area placed particular demands on the inventiveness of Hendriks precon. "One of the inner boxes can also be moved away at an angle to make the core easily accessible for cleaning, maintenance and the installation of infill parts."
Martin Pieterson continues: "The outer walls of the mould are mounted on wheels so that they can be opened and closed using hydraulic cylinders. All walls are equipped with an axle that protrudes through the perpendicular wall when closing. The outer wall is then automatically secured using hydraulic wedges, of which there are 12 in total on the mould. This saves us a lot of labour. Because 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 as a separate element with the station. All stations are fully equipped and installed in the field, but the separate roof design allows a component to be replaced in the field via the roof if necessary.
When asked about the collaboration with Hendriks precon, Martin Pieterson responds enthusiastically: “Working with Hendriks precon is very enjoyable. These moulds require a high degree of precision and a great deal of engineering expertise to function properly. Hendriks precon has mastered this like no other. Once again, they have developed an elegant solution for incorporating the large amount of hydraulics required to release the core into the core parts. A tough challenge and a major achievement.”
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