ESAB offers a number of cutting and welding solutions that provide controlled quality in the fabrication of on and offshore wind towers. From the initial oxy-fuel or plasma plate cutting and marking, ESAB provides a comprehensive range of welding technologies and customised packages for wind tower manufacturers.
Efficient wind tower production requires a smooth manufacturing flow on the workshop floor. If the fabrication process is interrupted unnecessarily, productivity drops and costs increase. The benefits to be gained from individual processes such as welding are lost and therefore it is essential to utilise proven technology from a recognised industry expert.
ESAB products can provide a range of sequential welding operations integral for the wind tower production process. Using ESAB as a dedicated supplier of products that offer high deposition rates, large projects can be executed efficiently with reduced welding costs and increased productivity, ensuring agreed production schedules and delivery dates are met.
ESAB offers welding technology to cover the rolling, forming and tack welding of the shell; external and internal longitudinal submerged-arc welding using a column and boom; manual MAG welding or submerged-arc welding of flanges and supports; hydraulic forming of shell sections when tack welding; joining of shell sections using roller beds or a head and tailstock positioner; external submerged-arc welding performed by a column and boom station; joining of shell sections using an ESAB Tripletrac; a tractor unit specially designed for internal welding; automatic welding of door frame using an ESAB Frametrac, a MIG/MAG welding tractor specially designed for travelling along a door frame.
ESAB can also provide solutions for the production of sub components, such as gear box housings, using an ESAB positioner and manual welding equipment.
High productivity welding, with deposition rates of up to 40 kg/hour using a tandem twin submerged-arc welding head, is possible. A dedicated wire and flux combination can eliminate major obstacles such as reduced impact strength in the weld, and poor slag release in narrow joints. ESAB OK 12.22 wire and OK 10.72 flux give good impact strength at minus 50 degrees, to satisfy offshore wind tower applications.
