SMarT Foundation Kits for the new Skystream 600 will reduce construction labor by one-half and save 15% or more in materials compared to traditional mat foundations for monopole towers. That is what our latest estimates indicate, with a resulting savings of more than 25% in the installed cost of Skystream foundations.
We are unable to anticipate every selection an installer might make, but we do know that the Skystream 600 will require larger wire sizes than the Skystream 3.7. Therefore, the new kits will include 1-1/2” (38 mm) PVC electrical fittings instead of the 1” (25 mm) fittings in previous kits. We will also include 1-1/2” (38 mm) electrical conduit and couplings sufficient to extend beyond the excavation. This may eliminate foundation construction delays in some cases.
To provide options for the installer, and to accommodate Skystream 3.7 installations, the new anchor rod templates have holes pre-drilled to accept both 1-1/2” (38 mm) and 1” (25 mm) PVC electrical conduit.
Extensive research and testing has led to new specifications and dosages for our fiber reinforced concrete. Four manufacturers have qualified their fibers for use in our SMarT Foundations: Novomesh 950 synthetic fibers by Propex Concrete Solutions (orderexpress@propexusus.com): TufMax DOT synthetic fibers by ABC Polymer Industries (info@abcfibers.com); Dramix RC-80/60-BN steel fibers by Bekaert Corporation (susan.krausman@bekaert.com); and 
BASF MasterFiber FF3 steel fibers by Maccaferri, Inc. (www.maccaferri-usa.com). The new SMarT Foundation Drawings specify the required fiber dosages and provide contact information for these worldwide suppliers. AnemErgonics can also provide fibers in appropriate situations.
We recommend that installers check with their ready-mix concrete suppliers early in the construction planning process, thereby ensuring the greatest flexibility in price and delivery of reinforcing fibers.
SMarT Foundations for Skystream 600 have been engineered to achieve the greatest construction efficiency and the lowest installation cost. Required excavation depth is 42” (1067 mm) for Southwest Windpower supplied towers and wind speeds up to 120 mph (54 mps). For greater wind speeds, the excavation depth is 48” (1219 mm). 
The foundation kits are designed for 120 mph (54 mps) because that is sufficient for 97% of all U.S. installations.For winds speeds greater than 120 mph (54 mps), or for frost depths greater than 42” (1067 mm), the installer is required to fabricate an extension for the Lower Stanchion supplied with the kit. Details are explained in the new Instruction Manuals.
To accommodate the increased design forces of the Skystream 600, all foundation kits will now be supplied with embedded washers and capturing nuts for the bottom of the anchor rods that are placed in the concrete.
The new SMarT Foundation kits have not yet been approved for seismic zones C, D, E and F. In those rare cases, a design supplement will be required. Please contact your Southwest Windpower sales person at customerservice@windenergy.com or an AnemErgonics representative at info@anemergonics.com.
As a result of considerable research and testing, including third party anchor rod pullout tests and concrete flexural-strength tests, AnemErgonics has developed, in concert with Tower Engineering Professionals (TEP), a “white paper” explaining the benefits of fiber reinforced concrete. TEP (rglover@tepgroup.net) is authorized to share this information on a need-to-know basis with building authorities who seek clarification when permitting Skystream foundations.
“J-bolts” are often used in foundation construction. But in an effort to reduce price, weight and shipping cost, AnemErgonics launched an aggressive research project to improve this aspect of foundation installation. The result is a new concrete anchor system that is shipped concurrently with SMarT Foundation kits. This greatly simplifies shipping logistics and reduces cost. The entire system is delivered to the UPS or FedEx address provided by the end user.
Concrete anchors are required to connect the tower base flange to the concrete foundation. Our engineers and technicians have invested hundreds of hours researching anchor rod specifications, including materials, corrosion protection, washers, nuts and vibration resistance. They succeeded in designing a system that simplifies installation and significantly reduces price, weight and shipping cost compared to the methods used previously. We use anchor rods threaded at both ends, and our system complies with ASTM F1554 (rods), ASTM F436 (washers) and ASTM A563 (nuts). In keeping with prudent engineering practice and the recommendations of U.S. government agencies, we also supply vibration resistant locking devices. We are proud to use domestic steel in our anchor rods, which are manufactured in the U.S.A.
Anchor rods are shipped in two long boxes, each of which weighs approximately 60 lbs (27 kg). Each box contains four anchor rods and associated nuts, washers and vibration resistant locking devices. Mill certifications are included for the anchor rod material so that installers can choose appropriate installation specifications. All unused materials are either reusable or recyclable.
