The fabrication had a difficulty of it's own as the client wanted to inspect the fabricated tower before it was allowed to be shipped to site. The massive size of the tower also meant that it could not be shipped in a fabricated condition.

The solution to that was to assemble the four faces of the tower in the factory. Demonstrate the fabrication by assembling the smaller section i.e. top portion of the tower in the factory for client's inspection. Then disassemble the tower for shipping and re-assemble it on site.

The sides of the tower were 45 mtr. long and 14 mtr. wide. To accommodate the entire tower on our shop floor, two pultrusion lines had to be temporarily shut down and kept aside so that the space can be utilized for this job. The photograph of the assembly process is self-explanatory.
  When the pultrusion was complete, life sized joints were prepared for testing and put on the universal testing machines until failure to confirm that they would survive the worst case conditions, and that too with a margin to spare.
When fabrication was completed, each section including the gusset plates were numbered, dissembled and packed for transport.
Testing and process control
  The testing of the tower was done at the following stages  
  • Raw materials: A strict control over the raw materials was exercised. The basic areas of control were the resin, and the adhesive. Glass and mats have a very high degree of standardization and hence manufacturers certifications were accepted
  • In process: Glass placement and degree of cure were the prime areas of inspection.
  • Fabrication: The testing during fabrication mainly involved around testing the tensile strength of the pultruded section, Lap shear strength of the adhesive under different bonding conditions and finally token testing of joints at full scale.
Transportation and erection at site
  The entire tower, including the gusset plates as well as the adhesive, weighed less than 10 tons. A 50 ft, 40-ton trailer truck was employed for transport mainly due to the long lengths of the members.  

The erection of the tower at site was duplication of the fabrication process employed in the factory. The numbered members of the tower side faces were laid down on the ground, arranged as per their sections and glued on ground to form sections that can be easily lifted and placed in it's position. The light weight as well as the incredible stiffness of the square tubes allowed easy lifting of sections. The other two faces of the tower were glued and bolted individually to the side faces.

The entire erection at site was completed within two months with the use of local labour, and a 100 ft derrick. Use of any mechanized lifting device was not needed at any stage of erection.

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