At Axzion, the quality and safety of our load handling equipment are paramount. To ensure this, we rely on rigorous testing and meticulous documentation. In this article, you will learn how Axzion conducts material and process testing and the comprehensive documentation that accompanies our products.
Weld Seam and Material Testing
Material and process testing provide additional security. Our work is inspected by our own or independent inspectors using the latest testing equipment. All certifications are, of course, available. We conduct tests during production, and the required final tests are always carried out by a neutral testing institute.
Magnetic Particle Testing
Magnetic particle testing is the most frequently used method for detecting surface and near-surface defects, such as hairline cracks, in magnetizable iron and steel materials. The flux leakage caused by magnetizing the component at surface cracks causes the magnetizable particles in the test medium to adhere. The effect is visible due to the contrast between the substrate and the test medium.
Dye Penetrant Testing
The dye penetrant method is one of the oldest non-destructive testing methods for detecting surface defects. The test can be performed on almost all metallic and non-metallic materials. In this method, the test liquid penetrates surface defects due to capillary action. After carefully washing off the solution, a developer layer is applied, drawing the liquid out of cavities and cracks, making the defect visible.
Ultrasonic Testing
The ultrasonic testing method is particularly suitable for detecting internal and external defects in sound-conductive materials throughout the entire cross-section of the workpiece. This acoustic method for non-destructive material testing is used for quality assurance of pipes, weld seams, and cast components, as well as for determining wall thickness.
Charpy Impact Test
How tough can a material be? Charpy impact tests are conducted to assess the toughness of a metallic material, even at the lowest temperatures. SpanSet Axzion works closely and in partnership with major testing organizations such as TÜV, DEKRA, Lloyd’s Register, and DNV GL. New designs are often discussed in advance, and the required safety measures are jointly determined.
Regular Inspections and Certifications
Inspectors are almost daily on-site to conduct the necessary construction supervision of large load handling equipment or to accompany the required load tests. The requirements in the offshore sector are enormous—all slings and load handling equipment must always be tested with an overload. The intense continuous loads caused by waves, wind, and difficult operating conditions place particularly high demands on the lifting equipment. Proven safety is paramount here. Turbines, gas compressors, and wind turbines are loads with very high value. Damage during transport must not occur under any circumstances, as the extremely long repair and replacement times would cause dramatic economic damage.
3,000-Ton Test Stand
Overload tests of very large lifting constructions have been extremely difficult and costly until now. For example, a floating crane had to be hired to test a large 800-ton lifting beam. A total of ten people were employed over several days to attach the test weights and conduct the test. The total costs for this load test exceeded the value of the delivered lifting solution many times over. The test facility is 12 meters long, 15 meters high, and weighs more than 200 tons. The maximum tensile force of 3,000 tons is applied by two huge hydraulic cylinders. The tank volume of the hydraulic unit is as large as the heating oil tank in a single-family house basement. The load tests are controlled manually or by PLC.
Correct Manufacturing, Comprehensively Proven
Documentation is just as important as the manufactured product. In the international steel and mechanical engineering industry, the materials used must be accurately verified; an undocumented component can lead to the rejection of the entire load handling equipment. Therefore, complete documentation is always part of the scope of delivery of a load handling device. The information and scope must correspond to the current status of the load handling equipment. Proof of the quality of the components and materials used, as well as the tests conducted, must be included. For simple standard solutions, a ready-made template can be used. Complex solutions require a customized instruction manual. Documents from various sources must be compiled for this purpose, and the contents are "laid out" by hand like print documents. The correction workflow takes place through many channels, such as email and telephone, making it tedious and time-consuming.
With Axzion's document management, documentation is generated, managed, and archived semi-automatically, and the workflow between the customer and the manufacturer is organized. Content is prepared as an editorial part separately from the design and is only merged into a PDF upon export. The documents produced in this way are archived within the system and can be viewed and sent from there.