The challenge
The roof trusses of a clinker hall carry thermal loads, vibration from the tripper conveyor and heavy dust deposits that trap moisture against the steel.
This leads to fatigue cracks at welded nodes, section loss from corrosion and loosened bolts. The trusses span live stockpiles, so the only way to reach them during operation was by rope access.
Scope of works
- Dual-rope rope access giving full 3D access to chords, diagonals and gusset plates
- Local removal of clinker crusts to expose bare steel for testing
- Visual testing and ultrasonic thickness measurements compared with the design drawings
- Inspection and calibrated torque testing of bolted splices to EN 1090-2
- Dye penetrant testing of high-stress node welds
Outcome
The plant now has a complete NDT baseline for the trusses, loose joints were re-torqued and repairs targeted, with the conveyors running throughout. See the clinker roof build-up cleaning and our NDT services.
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