Poloidal Field Coils Winding Facility
The first completed building on the °ÄÃÅÁùºÏ²Ê¸ßÊÖ platform was the Poloidal Field Coils Winding Facility (2011). The European Domestic Agency built this facility for the winding and production of °ÄÃÅÁùºÏ²Ê¸ßÊÖ's four largest poloidal field coils. Today, the building houses activities related to machine assembly.
The large red-topped manufacturing facility located on the east side of the construction platform housed the assembly of °ÄÃÅÁùºÏ²Ê¸ßÊÖ's four largest poloidal field coils, part of °ÄÃÅÁùºÏ²Ê¸ßÊÖ's magnetic confinement system. Ranging in diameter from 8 to 24 metres, they were simply too large to be transported in their finished state.
The Poloidal Field Coils Winding Facility accommodated docking stations for the unloading and temporary placement of the superconducting coils, production zones corresponding to the successive steps of the winding and assembly process, and offices. Two overhead travelling cranes worked from opposite ends of the building to manipulate and transport the heavy loads and a third heavy-lift gantry crane was installed for the final assembly stages.
Construction of this concrete and steel structure began in August 2010 and was completed in December 2011. The building's metal cladding—five layers of metal sheeting and insulation—was designed to isolate the shop floor, where cleanliness was a priority, from the dust of the platform. After qualification activities in 2016/2017, the teams began the series production of double pancakes, which are flat, spiralled coils that are stacked in layers to form the coil winding packs. The complete process, from winding to finished coil, required approximately two years per coil.
Production activities have ended and the facility has been reconverted for activities that support °ÄÃÅÁùºÏ²Ê¸ßÊÖ machine assembly.
For more information on poloidal field coil manufacturing see this page.
Winding Facility facts:
- Construction: August 2010-December 2011
- Surface area: 12,000m²
- Dimensions: 257 metres long, 49 metres wide, 18 metres tall
- Floor slab: 40 cm thick, designed to withstand 42 tonnes/m²
- Lift capacity of bridge cranes: 25 tonnes, 100 tonnes
- Gantry crane lift capacity: 400 tonnes
- Beginning of qualification activities: 2016
- Coil fabrication: April 2017-March 2024
Photo Gallery
Last photos before activity
2015-05-30 - Professional photographer Christian Luenig took a series of interior shots of the Poloidal Field Coils Winding Facility in May 2015. Photo: Christian Lünig/ VG Bild und Kunst (Follow all manufacturing news at /construction/SiteFabricationPFcoils
Christian Luenig series
2015-05-30 - Photo: Christian Lünig/ VG Bild und Kunst
The doors open
2014-01-13 - Conductor for the commissioning of the Winding Facility enters through the north door. It will be stored until the manufacturing line for the poloidal field coils is in place.
Delivery from China
2014-01-13 - Following a first convoy in June 2013, a second delivery of qualification conductors from China reached the Poloidal Field Coils Winding Facility on 17 January. This material will be used for cabling and coil manufacturing process qualification.
Future factory
2013-01-11 - 49 metres wide, 257 metres long: the Winding Facility will house the different assembly stations for °ÄÃÅÁùºÏ²Ê¸ßÊÖ's large poloidal field coils. Photo: F4E
Heavy lift equipment for large components
2012-12-20 - The 40-tonne circular spreader beam can travel the length of the building to move the poloidal field conductor assemblies from the winding station, on to impregnation with epoxy resin, and finally stacking and joining.
December 2012
2012-12-06 - The sharp light of December illuminates the Poloidal Field Coils building and casts long shadows ...
Seen from 40 metres
2012-12-03 - The winding facility for the poloidal field coils is the first completed building on the °ÄÃÅÁùºÏ²Ê¸ßÊÖ platform. Opposite the facility is a 3,500 m² area under development for the contractors that will be responsible for the next major project: the civil engineering works on the Tokamak Complex. © Sylvain Couturier
Site in September 2012
2012-09-13 - Looking across the platform from the completed winding facility at the Assembly Hall worksite (mid-platform) and the new °ÄÃÅÁùºÏ²Ê¸ßÊÖ Headquarters (background).
Strange exhaust unit
2012-06-21 - This Darth Vader-like structure sitting on the roof of the Poloidal Field Coils Winding Building is one of several exhaust fans that will suck air out of the vast building.
Doors are closed for now
2012-06-21 - The building that will house the on-site assembly line for five of °ÄÃÅÁùºÏ²Ê¸ßÊÖ's six poloidal field coils stands ready on the southeast edge of the platform for activity to begin at the end of the year.
Before the equipment moves in
2012-06-08 - In June, a group of visitors from Sweden is treated to a tour of the PF Winding Facility.
An on-site facility for gigantic components
2012-05-31 - From the north end of the facility, the gigantic coils won't have far to go to enter the Assembly Hall, which will be built on the near side of the Tokamak Seismic Pit. Photo: F4E
Ready for the delivery trucks
2012-05-31 - The area around the PF Winding Facility is now paved. In 2013, trucks carrying the first conductor spools from China, Europe and Russia will enter this end of the building to deliver their loads. Photo: F4E
2012-05-31 - Water for the Winding Facility's firefighting system is stored in this cylindrical tank. Photo: F4E
The only manufacturing building
2012-05-31 - This 257-metre-long building will be equipped with three manufacturing stations. The sequential operations necessary for completing one poloidal field coil will take at least 24 months. Photo: F4E
Not for long
2012-04-20 - The Poloidal Field Coils Winding Facility will not be the only building on the platform for long: the contract for the three-building Tokamak Complex (Diagnostic, Tritium and Tokamak buildings) will be signed later this year. Photo: Engage-AP
All is quiet
2012-03-15 - The completed Poloidal Field Coils Winding Facility awaits busier days. Later this year, the selected coil manufacturer will move in to equip the building. Photo: F4E
It's done
2012-02-01 - Snow hasn't hampered the works on the Poloidal Field Coils Winding Facility: the building is now completed and awaits handover from the building contractors (the French consortium Spie Batignolles, Omega Concept and Setec) to the European Domestic Agency for °ÄÃÅÁùºÏ²Ê¸ßÊÖ, Fusion for Energy.
Exterior work completed
2012-01-12 - Roadwork has now been completed around the Poloidal Field Coils Winding Facility.
Operations to begin this year
2011-12-21 - The completed interior of the Winding Facility. In this 257-metre-long building work will begin in late 2012 on the winding and assembly of five poloidal field coils (PF2, 3, 4, 5 and 6). Photo: F4E
Bring out the heavyweights
2011-12-21 - Heavy winches and cables support the weight of the 40-ton spreader beam, which will be used during the assembly stage of coil manufacture. Photo: F4E
Drive on in!
2011-12-12 - Trucks delivering the raw material for coil manufacture—niobium-titanium conductor—will enter the facility through this door and unload in a dust-free environment. Photo: F4E
Offices ready
2011-12-12 - Office space for 100 people is located along the south-eastern wall of the building. Photo: F4E
Last completed edge
2011-12-12 - Exterior stairwell, paved roads ... the last touches to the Poloidal Field Coils Winding Facility are carried out before handover on 14 February. Photo: F4E
One year of progress in a picture
2011-12-08 - The three projects that transformed the °ÄÃÅÁùºÏ²Ê¸ßÊÖ platform in 2011: the PF Coils Winding Facility (foreground); the Tokamak Pit excavation and foundation work (centre); and—in the distance—the °ÄÃÅÁùºÏ²Ê¸ßÊÖ Headquarters.
Cladding operations end
2011-11-23 - The bright colours of the Winding Facility disappear as the last layer of cladding is put into place.
Nearly 200 tonnes
2011-11-18 - The spreader beam (40 tonnes) is supported by a trolley (48 tonnes) that runs between two steel beams (43 and 48 tonnes). The entire assembly weighs close to 200 tonnes. Photo: F4E
257 m x 49 m x 18 m
2011-11-18 - Cladding operations are completed on the north end of the Winding Facility. The 257 m x 49 m x 18 metre facility required 9,500 square metres of steel cladding and 11,000 square metres of roofing. Photo: F4E
A spreader beam to carry the completed coils
2011-11-15 - This 25 metre-wide spreader beam has 24 brackets that will bear the weight of the poloidal field coils as smoothly and evenly as possible, and avoid tilt. Photo: F4E
Metal-frame building
2011-11-15 - The weight of the Winding Facility's metal structure is 1,000 tonnes. Each of the rooftop heating and ventilation units weighs a further 9 tonnes.
Final stages
2011-11-15 - With one month to go before work on the Poloidal Field Coils Winding Facility ends, workers carry out the last cladding operations on the north face of the building. In the foreground, a cylindrical tank that will store water for the Facility's independent fire fighting system.
Across the platform ...
2011-11-15 - The Winding Facility is situated on the far end of the 400 metre-wide °ÄÃÅÁùºÏ²Ê¸ßÊÖ platform. In seven years, what is now empty space will be entirely filled in with the infrastructure and installations in support of the °ÄÃÅÁùºÏ²Ê¸ßÊÖ Tokamak.
Slowly but surely
2011-11-10 - In November 2011, static load and dynamic movement tests were carried out on the 40-tonne spreader beam, which must be capable of transporting loads as smoothly and evenly as possible, with a maximum authorized tilt of 10 mm. Photo: F4E
This is the "delivery" end of the Winding Facility
2011-10-26 - Spools of niobium-titanium conductor will be delivered here at the south end of the facility. Winding operations will happen in a sequential manner until the finished coils leave the opposite end of the building on a self-propelled transporter. Photo: F4E
Seen from the °ÄÃÅÁùºÏ²Ê¸ßÊÖ Visitor Centre
2011-10-26 - Four hundred metres across the platform, the first completed building. Work will begin here in 2012 to wind °ÄÃÅÁùºÏ²Ê¸ßÊÖ's largest magnets: the poloidal field coils. Photo: F4E
Rainbow in October
2011-10-25 - An October rainbow briefly illuminates the °ÄÃÅÁùºÏ²Ê¸ßÊÖ platform and the near-completed Poloidal Field Coils Winding Facility.
Installation takes two days
2011-10-06 - Following delivery from the factory in San-Sebastian, Spain, the second travelling crane of the Poloidal Field Facility is installed in two days. Photo: F4E
The "heavyweight" travelling crane for finished components
2011-10-06 - The first beam (43 t) is joined by the second (48 t) and between the two a hoisting trolley is installed. Photo: F4E
Completed interior
2011-10-06 - Interior painting is finished; in 2012 this building will be fitted out with equipment for the winding of °ÄÃÅÁùºÏ²Ê¸ßÊÖ's poloidal field magnets. Photo: F4E
The central trolley
2011-10-06 - The central trolley (48 tonnes) will support the weight of the 40-tonne spreader beam and allow it to transfer loads across the width of the Winding Facility. Photo: F4E
Assembling the second crane
2011-10-04 - Components for the second bridge crane—two 40-tonne beams and a hoisting trolley (seen on the floor)—are delivered to the °ÄÃÅÁùºÏ²Ê¸ßÊÖ site in October. Photo: F4E
Here's the second crane
2011-10-04 - The first 40-metre steel beam—part of the Winding Facility's second travelling crane—is lifted onto the waiting rails. Photo: ENGAGE.AP
A fresh coat of paint
2011-09-27 - Floor surface treatment is completed on one-half of the Winding Facility. The travelling crane, in yellow, will have the capacity to travel the entire length of the building. Photo: F4E
Work on the exterior areas
2011-09-27 - Finishing touches are made to the south end of the Poloidal Field Coils Winding Facility and work begins to pave roads. Photo: F4E
Test power and HVAC in October
2011-09-14 - The Winding Facility is just a few months from completion. Scheduled for October: power, HVAC (heating and air conditioning) and fluid tests; the delivery of the second bridge crane, and painting inside the building. Photo: Altivue/°ÄÃÅÁùºÏ²Ê¸ßÊÖ Organization
Completed in December
2011-09-14 - The north face of the Poloidal Field Coils Winding Facility will remain open until the final bridge crane is delivered in October and installed directly on the rails. Photo: Altivue/°ÄÃÅÁùºÏ²Ê¸ßÊÖ Organization
Floor preparation
2011-09-12 - Workers "shotblast" the floor to prepare for painting operations in September 2011. Photo: F4E
Once finished ...
2011-09-01 - Integrated into the west face of the Winding Facility: two large exit doors for the completed coils. Photo: F4E
The inside of the winding facility
2011-09-01 - The Poloidal Field Coils Winding Facility is 257 metres long, 49 metres long and 18 metres high. Photo: F4E
On schedule
2011-09-01 - Work to finish the Winding Facility progresses as scheduled; delivery is on time for December 2011. Photo: F4E
And now, the windows
2011-08-11 - Windows are installed along the top of the Winding Facility in August 2011. Photo: F4E
Waiting for the second bridge crane to arrive
2011-08-11 - The far end of the Winding Facility will be closed up after the delivery of the second bridge crane in October. Photo: F4E
One year later
2011-08-11 - The Poloidal Field Coils Winding Facility in August 2011. Photo: F4E
Five months from finish
2011-07-28 - Work advances rapidly on the 257-metre-long Poloidal Field Coils Winding Facility in July 2011: the cladding is nearly finished, the three-floor office building is in place ... Photo: F4E
Cladding activities on the south-east side
2011-07-28 - Corrugated metal on the inside, plus two layers of glass wool insulation and two layers of metal sheeting sealed with tape—these five layers make up the walls of the Poloidal Field Coils Winding Facility. Photo: F4E
Offices are in
2011-07-28 - Three storeys of office space, in white, have been installed along the Winding Facility's east face. Photo: F4E
Final colours
2011-06-20 - On the south face of the Poloidal Field Coils Winding Facility, the last layer of cladding has been set into place. Photo: F4E
Tower cranes in the distance
2011-06-20 - From the roof of the Winding Facility, the tower cranes working around the Seismic Isolation Pit (blue) and the °ÄÃÅÁùºÏ²Ê¸ßÊÖ Headquarters (yellow) are visible in the distance. Photo: F4E
The Winding Facility in June 2011
2011-06-20 - Even the Technical and Production Buildings on the eastern side of the Winding Facility are covered with metal cladding. Photo: F4E
Successive layering
2011-06-20 - Successive layers of cladding can be distinguished in this photo taken in June 2011. Photo: F4E
Heavy lifting
2011-06-07 - The heavy lifting required for poloidal field coil assembly will be done by the overhead bridge cranes. Beams for the first crane arrive on site in June 2011. Photo: AIF
Special delivery for the Winding Facility
2011-06-07 - This 38.3 metre-long steel beam is one of two beams delivered in June 2011 for the Winding Facility's 25-tonne travelling crane. Photo: AIF
Placed overhead on the south end of the facility
2011-06-07 - Straddling the workspace across its width (approximately 40 metres) and installed at opposite ends of the Winding Facility, two overhead cranes will travel along metal rails that span the building's entire length, lifting loads up to 25 and 100 tonnes resepctively. Photo: AIF
Approximately 6 months from completion
2011-05-27 - Looking out from the first structure to go up on the °ÄÃÅÁùºÏ²Ê¸ßÊÖ platform. Photo: AIF
Three storeys of office space
2011-05-27 - A small pre-fabricated structure will installed along the back side of the building for offices and administrative services. Photo: AIF
Taking on its final appearance
2011-05-27 - With the exception of the right edge, where yellow insulation and the first layers of cladding are still apparent, the Poloidal Field Coils Winding Facility takes on its final colours. Photo: AIF
As the clouds roil ...
2011-04-28 - On a stormy day, the colourful layers of cladding of the Poloidal Field Coils Winding Facility.
Cladding on the south face
2011-04-21 - Successive layers of cladding are applied to the exterior of the Winding Facility in April 2011. These include an inner layer of sheeting containing small holes to absorb work area noise; two layers of glass wool insulation; and finally two layers of metal sheeting sealed with tape against dust. The final colours will be grey and burnished red.
Building #1 of 39
2011-04-21 - The first of 39 buildings on the °ÄÃÅÁùºÏ²Ê¸ßÊÖ platform: the Poloidal Field Coils Winding Facility.
The Winding Facility in April
2011-04-17 - Seen from above: the Poloidal Field Coils Winding Facility. Photo: Altivue/Spie Batignolles
Four layers of rooftop insulation
2011-04-17 - The roof of the Winding Facility is covered with four layers of insulation: steel, rock wool, elastomer, and tar. Photo: Altivue/Spie Batignolles
Successive production zones
2011-04-17 - The Winding Facility will accommodate docking stations for the unloading and temporary placement of the superconducting coils, production zones corresponding to the successive steps of the winding and assembly process, and offices. Photo: Altivue/Spie Batignolles
Seen from the sky
2011-04-17 - The poloidal field coil system consists of six horizontal coils placed outside the toroidal magnet structure. Due to their size, the actual winding of five of the six poloidal field coils will take place here, in this dedicated, 257-metre long facility on the °ÄÃÅÁùºÏ²Ê¸ßÊÖ site in Cadarache. (The smallest of the coils will be manufactured offsite and delivered finished.) Photo: F4E
Where is the exit?
2011-04-17 - A smooth concrete platform is built outside of the exit doors of the Poloidal Field Coil Winding Facility for the safe transfer of the completed coils. Photo: Altivue/Spie Batignolles
12,000 square metres
2011-04-13 - A surface area of 12,000 square metres dedicated to the winding and assembly operations of °ÄÃÅÁùºÏ²Ê¸ßÊÖ's poloidal field coils. Photo: F4E
Construction in 18 months
2011-04-13 - Some 80 workers are involved in the construction of the Poloidal Field Coils Winding Facility, which will be completed in December 2011. Photo: F4E
Concrete works end in April
2011-04-13 - All concrete for the Winding Facility is poured by April 2011. Photo: Altivue/Spie Batignolles
What role for the poloidal field magnets?
2011-04-13 - The poloidal field magnets pinch the plasma away from the walls and contribute in this way to maintaining the plasma's shape and stability. Photo: F4E
Cladding work begins
2011-04-13 - Work begins on the metal cladding of the Winding Facility. Five layers of metal cladding and insulation will protect the work space inside—where cleanliness is a priority—from the infiltration of dust. Photo: F4E
Preparing for the travelling cranes
2011-03-17 - Embedded plates will be installed along the horizontal beams on either side of the Poloidal Field Coils Winding Facility for the rails of the travelling cranes. Photo: F4E
Looking north
2011-03-10 - Looking north past the Poloidal Field Coils Winding Facility on the eastern edge of the °ÄÃÅÁùºÏ²Ê¸ßÊÖ platform. Photo: F4E
Technical areas for production
2011-03-10 - The Technical (electricity) and Production (cooling water, chiller, boiler) Buildings go up alongside the main Winding Facility. Photo: F4E
Floor slab nearly completed
2011-03-10 - Designed to carry loads of up to 42 tonnes per square metre, the floor slab for the Winding Facility is completed in March 2011. To ensure such high resistance, the subsoil was treated with a special hydraulic binder before reinforcement was laid and concrete poured. Photo: F4E
257 metres long
2011-03-10 - The 257-metre Poloidal Field Coils Winding Facility stretches off into the distance ... Photo: F4E
The last floor segment
2011-03-02 - Ready to cast the last of the concrete floor in the Poloidal Field Coils Winding Facility in March 2011.
Nineteen metres overhead
2011-03-02 - Working on the steel roofing trusses of the Winding Facility.
Roofing elements delivered
2011-02-24 - On the far end of the Winding Facility, cranes have delivered roofing materials ...to the roof. Photo: F4E
Giant exit doors
2011-02-24 - Five of °ÄÃÅÁùºÏ²Ê¸ßÊÖ's six poloidal field coils are too large to be transported and will be wound on site in the Poloidal Field Coils Winding Facility. The finished coils, measuring up to 24 metres in diameter, will leave the building through one of two 30-metre exit doors (visible at left in the photo). Photo: F4E
Underground networks
2011-02-24 - Trenches for the underground networks of the Poloidal Field Coils Winding Facility are dug in the foreground; in the background—the current office buildings of the °ÄÃÅÁùºÏ²Ê¸ßÊÖ Organization. Photo: F4E
State-of-the-works in February 2011
2011-02-24 - Looking into the Poloidal Field Coils Winding Facility in February 2011. Photo: F4E
950 tonnes in the roof
2011-02-03 - Thirty-four steel trusses spanning the 40-metre width of the Poloidal Field Coils Winding Facility: 950 tonnes in all. Photo: F4E
Part of Europe's commitment
2011-02-03 - The Poloidal Field Coils Winding Facility is financed by Europe, who will carry out the winding operations for the poloidal field coils in this building from superconductor delivered by China, Europe and Russia. Europe is responsible for the construction of all of the buildings on the °ÄÃÅÁùºÏ²Ê¸ßÊÖ platform as part of its commitment to the °ÄÃÅÁùºÏ²Ê¸ßÊÖ project. Photo: F4E
A building for winding and assembling
2011-02-03 - In this vast building, the operations for the winding and assembly of the poloidal field magnets will be carried out in successive order. The finished coils will exit one of the large openings in the west wall, for transfer to the Assembly Hall of the Tokamak Building. Photo: F4E
Roof trusses progress quickly
2011-02-03 - Construction of the metal framework has been underway for several weeks. It consists of a strong triangular shaped lattice with a 40-metre-long base. Photo: F4E
Thirty-four steel trusses
2011-01-14 - Each steel roofing truss is 4 metres high and 40 metres wide. Thirty-four trusses in all will support the roof of the 257-metre-long Poloidal Field Coils Winding Facility. Photo: F4E
And now, on to the roof
2011-01-14 - The metal trusses for the roof of the Poloidal Field Coils Winding Facility weigh eight tons each. Due to their weight, the metal parts are first assembled on the building's reinforced concrete slab, then lifted by crane to a height of 19 metres. Photo: F4E
The Poloidal Field Coils Winding Facility in January 2011
2011-01-14 - The Poloidal Field Coils Winding Facility in January 2011, after five months of construction. Photo: F4E
Working from the ground up
2011-01-01 - In January 2011, concrete pouring for the floor slab continues on one end of the building, while the first metal roof truss is set into place on the other. Photo: F4E
Posts and beams in place
2011-01-01 - The concrete pillars and beams of the Winding Facility are up and nearly all of the 12,000 m² floor slab has been set into place. The wide openings visible on the west face of the building are the exit doors for the completed coils; each door is 30 metres wide. Photo: Altivue/AIF
Nineteen metres high
2010-12-09 - Each of the Winding Facility's 62 concrete columns is 19 metres high. Photo: F4E
November fog
2010-12-01 - Concrete pouring activities continue despite the thick fog that covers the °ÄÃÅÁùºÏ²Ê¸ßÊÖ platform. Photo: F4E
Finishing touches
2010-12-01 - Workers smooth the wet concrete that has been cast for the floor of the Winding Facility. Photo: F4E
Every eight metres
2010-11-15 - Day by day, the 62 reinforced concrete columns are set into place, spaced every eight metres. Photo: F4E
Solidly anchored
2010-11-01 - The columns of the Winding Facility are solidly anchored four metres deep in the ground. These columns will support the structure of the building and bear the weight of two travelling bridge cranes that will have a lifting capacity, respectfully, of 25 and 100 tonnes. Photo: F4E
What operations for the Winding Facility?
2010-09-01 - Later 2012, the winding and assembly activities for °ÄÃÅÁùºÏ²Ê¸ßÊÖ's five largest poloidal field coils will begin in this 257-metre, on-site facility. Image credit: °ÄÃÅÁùºÏ²Ê¸ßÊÖ Organization
The largest components
2010-09-01 - The poloidal field coils completely encircle the °ÄÃÅÁùºÏ²Ê¸ßÊÖ vacuum vessel and toroidal field magnet system. These giant components are—for five of them, at least—too large to travel after manufacture. Image credit: °ÄÃÅÁùºÏ²Ê¸ßÊÖ Organization
The first building on the °ÄÃÅÁùºÏ²Ê¸ßÊÖ platform
2010-09-01 - Work begins on the first building on the °ÄÃÅÁùºÏ²Ê¸ßÊÖ platform in August 2010: the Poloidal Field Coils Winding Facility. The French consortium Spie Batignolles, Omega Concept and Setec was chosen by the European Domestic Agency F4E to design and build the facility. Photo: Altivue/AIF