The TWI project team produced test-specific risk assessments and agreed a test procedure. The qualification requirements set for the new connector were demanding and included applying static tensile loads of 9900 kN (1010 tonnes), fatigue loading at three different load levels and a test involving disconnecting the connector while under a tensile load. SRP also wished to measure the strain experienced by the fingers in the connector during the application of the pre-load, and during the external load tests.
TWI’s first task was to apply strain gauges to the fingers. Project engineers chose suitable gauges and applied these to the fingers at agreed locations. These were used to measure the strain experienced by the fingers during application of the pre-load and during the subsequent tests.
The team helped next by designing and assembling a test machine capable of applying a static load of up to 1010 tonnes, and fatigue loads of up to 500 tonnes, and working with SRP to design end fittings to fix the connector to the test machine. The following tests were carried out on the fully calibrated equipment: