MasterFlow 9500 for offshore wind turbines was awarded a DNV GL Type Approval certificate.
An ultra-high strength, high-performance offshore grout, MasterFlow 9500 from Master Builders Solutions by BASF, is the first product of its kind to receive a DNV GL (Det Norske Veritas Germanischer Lloyd) certificate for offshore concrete structures. This type approval certificate issued by the international test and certification body, which specialises in oil, gas and maritime services as well as in energy and sustainability, officially confirms the quality of the offshore performance grout.
“Being the first to receive this certificate feels like having received an award,” says Luc Westhof, global key account manager for wind turbine grouts at BASF. “The certificate assures that MasterFlow 9500 has been developed, tested and produced to the highest standards in the industry, and it also guarantees maximum reliability across the entire lifetime of the offshore wind farm.”
MasterFlow 9500 is a so-called exa-grout, with documented fatigue performance for time saving and durably secure grouting of offshore wind turbines’ foundations. The fast curing feature of the grout and its tolerance to very low temperatures speed up the installation process and prolong the timeframe for installation.
Throughout the certification process, experts from BASF and DNV GL worked on testing and documenting material properties, assessing quality control during the manufacturing process, product application and related installation guidelines as well as quality assurance documentation.
Project manager Andreas Lervik from DNV GL says: “BASF has successfully completed an extensive certification programme for their material, MasterFlow 9500. It is considered as a suitable material for use in load-carrying grouted connections when applied in accordance with the approved procedures and within the stated application limitations.”
The evaluation of MasterFlow 9500 was conducted in accordance with DNV-OS-C502 (Section 9E). A detailed summary of the material properties and conclusions from the certification process of MasterFlow 9500 is stated on the DNV Type Approval Certificate (No. K-5944, issued 2014-08-05).
Faster installation, protected investment
In addition, MasterFlow 9500 reduces the overall costs of offshore installations. The material quickly develops a high strength and can be applied at lower temperatures compared to conventional products. Considering the total cost of implementation, the time MasterFlow 9500 can save is a big factor in lowering the costs.
Also, provided the product is applied correctly, MasterFlow 9500 ensures a maintenance-free connection between the tubular steel members for offshore wind turbine foundations.
MasterFlow 9500 was recently used on the West of Duddon Sands wind farm project in the United Kingdom, where 108 monopile foundations were installed in a record-breaking period of just five months. In 2013, the performance grout was applied on the Gwynt-Y-Môr project with 160 monopiles in the Irish Sea as well as in the grouting of numerous test and demonstration turbines from several manufacturers, including the world’s currently most powerful offshore turbine with a rotor diameter of 164 metres and a capacity of eight megawatts.
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