With the increasing capacity of wind turbines, the application of concrete towers is gradually widespread. Although concrete towers have many years of application experience, they have not been applied on a large scale; The number of applications is small, and the design, supply chain, installation and other links are not fully mature, resulting in frequent problems of concrete towers. Several projects were forced to be demolished due to quality problems with concrete towers, causing significant economic losses.
Common defects in the production and installation of mixing towers
Common concrete defects can cause safety hazards to fans, such as segment collapse, tilting, and shaking, which take a long time to repair and are costly.
- Common defects in the production process
Illegal welding of rebars
The number of rebars is insufficient and the spacing is too large
The protective layer is too small
The protective layer is too large
Segments are exposed
Segment cracks
Honeycomb surface
Cold seams
- Common defects during installation and operation
- Positioning embedded deviation misalignment
- Horn hole plugging
- Segment misalignment
- The segment annular seam transmits light
- Vertical cracks are formed at the vertical splicing joints
- Segment breakage and cracking
- …………
- Photographs of defects during the installation phase
Segment annular seam light transmission;
Vertical cracks occur at the vertical splicing joints
Mixing tower quality inspection methods and suggestions
In order to ensure the quality of the concrete tower, it is recommended to do the following inspections during the production and operation phases:
Methods for testing at the production stage
Run the stage detection method
Internal damage
Cold seam inspection
Cover thickness detection
Intensity ultrasound test
Mixed tower segment inspection/supervision of applicable engineering phases
Engineering construction phase
- Supervision of the construction process
- Specimen testing
- Construction quality checks
- Completion acceptance
- Cover thickness detection
- Crack depth and width detection
- Detection of steel bar diameter, spacing and quantity
- Segment strength testing
- Segment cold seam detection
O&M phase
- Basic inspection
- Crack inspection and detection
- Levelness check
- Sedimentation detection
- Perpendicularity detection
- Steel strand wire force detection
SGS provides comprehensive solutions for concrete towers
Since 2021, the new energy team has set up a team to study the quality management of mixed towers, and has formed a relatively complete comprehensive management plan for mixed towers. The quality of the mixing tower can be guaranteed from three levels:
- System and Process Assurance (QA)
From the design, production, transportation, installation, acceptance, operation and other processes and systems to ensure the quality of the mixing tower. For example, the factory capacity audit confirms whether the factory has the ability to produce qualified products stably from the aspects of personnel, equipment, system, and operation. From the transportation, installation, acceptance of all aspects of the audit, to evaluate the whole process and the scheme of the scientific and reasonable.
- Process Quality Management (QC)
When stricter quality control is required, process quality control can be used, including factory production supervision, transportation process supervision, arrival acceptance, installation process supervision and acceptance, etc. Process quality management is a methodological way to further prevent quality risks.
- Application of detection methods
Most of the work of process supervision is supervision and verification, and some hidden defects can not be found, when it is necessary to clarify the quality of the segment or installation, the quality of the concrete structure can be determined by means of detection. SGS can provide advanced and comprehensive concrete construction inspection services.
Advantages of SGS mixed tower detection
- The staff is professional and complete
SGS has a rich reserve of concrete testing personnel, including professional engineers for load and structural evaluation, inspection engineers who have been engaged in the concrete industry for many years, installation quality management engineers, and registered quality management personnel, who can solve the whole process of quality management services for you from design evaluation, production management, transportation and installation to the operation stage.
- Technologically advanced
SGS has also developed a low-frequency array concrete inspection method, which can accurately detect internal defects and rebar spacing in real time, accurately and intuitively. The comprehensive application of various detection methods can effectively control the quality of concrete towers and reduce risks.
- Rich track record
SGS mixing tower team has provided professional services for many domestic customers, including mixing tower manufacturers, design units, OEMs, and owners; The service content includes quality management, testing and analysis, failure analysis, etc.
If you have any questions about wind turbine foundation and civil engineering, please contact SGS, and we will give you professional advice and services.
About SGS:
Founded in 1878, SGS is an internationally recognized testing, inspection and certification organization, headquartered in Switzerland, with more than 99,600 employees worldwide and a global network of more than 2,650 branches and laboratories. SGS-CSTC Standards Technical Services Co., Ltd. was established in 1991 by SGS Group and China Standard Technology Group, which is affiliated to the State Administration for Market Regulation, and has built 90 branches and more than 200 laboratories across the country, with more than 16,000 well-trained professionals.
SGS wind energy services started in Europe, the leading wind power technology, and set up the SGS Wind Energy Competence Center in Germany, with a large number of industry experts and strong technical research and development capabilities. Relying on advanced testing methods, senior industry experience and global service network, SGS is committed to providing inspection, testing, identification and certification services for all stakeholders in the wind power industry. Our service models include: product certification, design review, equipment supervision, equipment inspection and installation supervision, material and spare parts testing, non-destructive testing, construction and installation monitoring, wind turbine in-service services, failure analysis, technical due diligence, wind turbine life extension assessment, project certification, project management technical support, personnel training, quality consulting, etc.
SGS Industrial Services
Phone: 400 630 1878
E-mail: [email protected]