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Vertical assembly and

installation of 4-segment
anchor cage
Document no.: 0061-5844 V05
Class: RESTRICTED
Type: T09
Date: 2020-02-06

VESTAS PROPRIETARY NOTICE: This document contains valuable confidential information of Vestas Wind Systems A/S. It is protected by copyright law as an unpublished work. Vestas reserves all patent, copyright, trade secret, and
other proprietary rights to it. The information in this document may not be used, reproduced, or disclosed except if and to the extent rights are expressly granted by Vestas in writing and subject to applicable conditions. Vestas
disclaims all warranties except as expressly granted by written agreement and is not responsible for unauthorized uses, for which it may pursue legal remedies against responsible parties.
Vertical assembly and installation of 4-segment anchor cage
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Wind turbine type

Read the full document before you start to do work.


Send questions or concerns about the document to Vestas Wind Systems A/S.

Wind turbine type Mk version

V80-2.0 MW Mk 7

V90-1.8/2.0 MW Mk 7 and 8

V90-2.0/2.2 MW Mk 10

V90-3.0 MW Mk 8 and 9

V100-1.8/2.0 MW Mk 7

V100-2.0 MW Mk 9

V100-2.0/2.2 MW Mk 10

V100-2.6 MW Mk 9

V105-3.3/3.45 MW Mk 2

V105-3.45 MW Mk 3A

V110-2.0/2.2 MW Mk 10

V112-3.0 MW Mk 0 and 1

V112-3.3/3.45 MW Mk 2

V112-3.45 MW Mk 3A

V117-3.3/3.45 MW Mk 2

V117-3.45 MW Mk 3A

V117-4.0/4.2 MW Mk 3E

V120-2.0/2.2 MW Mk 11C

V126-3.3/3.45 MW Mk 2

V126-3.45 MW Mk 3A

V126-3.45 MW Mk 3B

V136-3.45 MW Mk 3B

V136-4.0/4.2 MW Mk 3E
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Wind turbine type Mk version

V150-4.0/4.2 MW Mk 3E

V150-4.0/4.2 MW Mk 3E3

Change description

Description of changes

Updated the wind turbine type table.


Added section 12.18 To use the template flange again, page 33.
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Table of Contents

1 Safety ........................................................................................................................... 5
2 Educational requirements of service technician .................................................... 5
3 Abbreviations and technical terms .......................................................................... 5
4 Referenced documentation....................................................................................... 6
4.1 Safety documents......................................................................................................... 6
4.2 Reference documents .................................................................................................. 6
5 Purpose ....................................................................................................................... 7
6 Note.............................................................................................................................. 7
7 Tools ............................................................................................................................ 7
8 Spare parts .................................................................................................................. 9
9 Consumables .............................................................................................................. 9
10 Weights........................................................................................................................ 9
11 Estimated time use..................................................................................................... 9
12 Procedure.................................................................................................................... 9
12.1 To prepare the foundation ............................................................................................ 9
12.2 To lift and to put the base flange segments in position................................................11
12.3 To do a check of VUI numbers of anchor bolts, nuts, and washers ........................... 13
12.4 To prepare the anchor bolts for vertical assembly...................................................... 14
12.5 To install the distance pipes together with anchor bolts ............................................. 15
12.6 To install the remaining anchor bolts vertically........................................................... 18
12.7 To get access to the top of the anchor cage............................................................... 19
12.8 To install the foam blocks ........................................................................................... 19
12.9 To install the template flange ...................................................................................... 21
12.10 To attach tags with VUI numbers................................................................................ 24
12.11 To install the fishplates ............................................................................................... 24
12.12 To tighten the remaining nuts at the base flange........................................................ 25
12.13 To do a check of and adjust the alignment ................................................................. 25
12.14 To prepare the anchor cage for concreting................................................................. 26
12.15 To prepare the anchor cage foundation for the handover .......................................... 28
12.16 To prepare the anchor cage foundation for the T-flange tower installation ................ 32
12.17 To do the grouting and the final tensioning of the anchor cage foundation................ 32
12.18 To use the template flange again ............................................................................... 33
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1 Safety 0011465016

All work relating to a Vestas wind turbine, including work methods and practices, employee
training and protective measures, and use of tools and equipment, shall be in accordance with
the requirements of the applicable governmental and private occupational safety and health
codes and standards. Employers engaged in such work are also required to be familiar with and
comply with the wind turbine-specific ‘Safety regulations for operators and technicians’ manual
for the relevant wind turbine type. Vestas shall not be responsible for any liabilities arising from
failure to comply with such requirements. Vestas reserves the right to inspect such work to
ascertain such compliance.
The service technician must read and understand the PPE sheets for each of the chemicals used
or work done in this instruction. The PPE sheets describe the correct personal protective
equipment to wear for the specific work. If in doubt about the PPE requirements for the work,
contact the site responsible or the line manager and confirm the correct procedure before starting
the work.
For chemicals that are not specified with accurate name and item no., contact the local site-
responsible person for information about PPE and other safety instructions related to the use of
the chemical.

2 Educational requirements of service technician 0011465014

At least 2 of the service technicians who do work in a wind turbine must be able to prove that they
have a valid GWO basic safety training certificate.
At least 1 service technician must hold the wind turbine-specific training course certificate for the
wind turbine in question.
Some tasks require one or more advanced training modules or job-specific training, as described
in the Vestas technical training programme. The person who plans a specific task must make
sure that the service technicians involved have the proper know-how for the completion of that
task.

3 Abbreviations and technical terms 0021872030

Table 3.1: Abbreviations

Abbreviation Explanation
ERP Enterprise resource planning
GWO The Global Wind Organisation
LDF Load distribution flange
LDST Large diameter steel tower
PE Polyethylene
PPE Personal protective equipment
PVC Polyvinyl chloride
SDS Safety data sheet
SIF Service inspection form
SPRA Standardised procedure risk assessment
VDB Vestas database
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Abbreviation Explanation
VUI Vestas unique identifier
WLL Working load limit

Table 3.2: Explanation of terms

Term Explanation
Distance pipes Pipes between the base flange and the bottom part of the foam.
Loose distance Pipes between the bottom of the foam and the bottom part of the template
pipes flange.
Short distance Pipes on the top of the template flange when LDF is used.
pipes
Site assembly Component assembly information.
drawing
VUI Number which ensures full traceability of an item.

4 Referenced documentation

4.1 Safety documents 0021872029

Table 4.1: Safety documents

Document no. Title


0001-0410 Personal protective equipment sheets
0004-4159 Standardised procedure risk assessment (SPRA)
Various Safety regulations for operators and technicians
Relevant SDS for the chemicals used in this document

4.2 Reference documents 0011653835

Table 4.2: Reference documents

Document no. Title


920098 Torque wrench settings
960501 Bolt connections
0005-8491 Construction of gravity foundation
0009-1539 Final tensioning of foundation anchor bolts
0010-8662 Recording of main components
0017-5653 Switchgear foundation guideline
0018-0710 Grouting of anchor cage 1.0 and 1.5
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Document no. Title


0019-1131 Replacement of tower flange bolt and tower anchor bolt
0035-2811 Installation of towers
0045-8646 Levelling of load distribution flange (Mk 2C)
0083-1032 Levelling of load distribution flange (Mk 3E)
0058-5234 Installation of HV switchgear
0060-6511 Installation of LDST split tower sections
0061-5845 SIF for vertical assembly of 2- and 4-segment anchor cage
0065-3482 Standard service tools
Various Site assembly drawing

Unless it is specified differently, see 920098 ‘Torque wrench settings’ for information
about bolt types and bolt lubrication, and see 960501 ‘Bolt connections’ for
information about torque values.

5 Purpose 0011533994

This document gives the procedure for how to assemble and install a 4-segment anchor cage in
vertical position.

SIF 0061-5845 ‘SIF Vertical assembly of 2 and 4 segment Anchor Cage’ must be
continuously filled out with required data and information.

6 Note 0025048668

This document is only applicable to installation of “AC1.5”. See the anchor cage drawing and
make sure that the anchorcage type is “AC1.5”.

7 Tools 0011587614

For standard service tools, see 0065-3482 ‘Standard service tools’.

Table 7.1: Tools

Item no. Quantity Description


VT730100 As necessary Electric impact wrench ¾ in. (230 V)
ERP: ELECTRIC IMPACT WRENCH 3/4"
299257 As necessary Electric impact wrench ¾ in. (110 V)
ERP: WRENCH, IMP ELEC 110V 9A 3/4" DRV
227791 1 42 mm fork spanner
ERP: FIXED SPANNER 41MM 894 DIN
227750 2 36 mm fork spanner
ERP: RING FIXED SPANNER 36MM ACESA
227794 1 55 mm fork spanner
ERP: FIXED SPANNER 55mm 894 DIN
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Item no. Quantity Description


VT200212 1 60 mm long-sleeve socket (36 mm anchor bolts)
ERP: SPEC TOP HEXAGON 60 FOR NUT
VT200213 1 70 mm long-sleeve socket (42 mm anchor bolts)
ERP: SPEC TOP HEXAGON 70 FOR NUT
238422 As necessary ERP: LOCK RING FOR IMP.SOCKET 3/4"
238470 As necessary 60 mm top (36 mm anchor bolts)
ERP: IMPACT SOCKET 60MM 1"
238473 As necessary 70 mm top (42 mm anchor bolts)
ERP: IMPACT SOCKET 46mm 1½"
VT187110 1 ERP: TORQUE WRENCH 40-200 Nm
VT187231 1 Torque wrench (140–760 Nm)
ERP: TORQUE WRENCH 140-760 Nm W CERT
238304 1 Ratchet head ¾ in.
ERP: RATCHET HEAD 3/4" 754-04 RIGHT
238480 As necessary Adaptor 1 in.-3/4 in.
ERP: IMPACT ADAPTOR 1"-3/4"
1 3 in. pipe wrench
As necessary Crow bar
1 Laser level
1 Tape measure
1 Stanley knife
1 Twister tool for thread binders
3 15 t lifting sling or chain with self-locking hook
3 Shackles for lift of the template flange segments with valid
WLL according to the total weight of the anchor cage
3 Swivel eye bolt (sufficient threaded bolt length) that has nut
and washer for the lifting of the base flange segments with
valid WLL according to the total weight of the anchor cage
1 Paint brush or a paint roller for application of Non-Naphtha
1 Tarpaulin

Some tools in this tools list can vary in shape and technical specification from region
to region due to local requirements.
If in doubt, contact your local tools warehouse for tools applicable to your region.
This note may not be applicable for any special tools used in this procedure.
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8 Spare parts 0011449219

Table 8.1: Spare parts

Item no. Quantity Description


None

9 Consumables 0011587613

Table 9.1: Consumables

Item no. Quantity Description


298200 As needed Non Naphta
ERP: NON NAFTA
As needed Duct tape, 5-metre roll
As needed Shuttering oil

10 Weights 0021872028

The weights of the anchor cage components are specified in the site assembly drawing.

11 Estimated time use 0011533992

At least 4 service technicians for 20–25 man-hours.

12 Procedure

12.1 To prepare the foundation 0021872027

1 Make sure that the blinding layer of the foundation is released and ready for use (surface of
the blinding layer must be smooth and level in this area).

2 Make a note of the position of the cable conduits that come in the centre line (location and
distances are specified according to the foundation centre). See 0017-5653 ‘HV switchgear
foundation guideline’ and 0058-5234 ‘Installation of switchgear’ for how to put the tower
door in the correct position in relation to the cable conduits.
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3 Make marks for the correct final position of


the base flange and the adjusting legs on the
blinding layer.

4 Put the adjusting legs on the blinding layer.

5 If it is a Vestas foundation design, install all reinforcement after completion of the anchor
cage installation. In this case, cut the mesh reinforcement pos. 13.2 to match the cable
conduits and the adjusting legs. See 0005-8491 ‘Construction of gravity foundation’ for
installation of the reinforcement.

6 If it is a Vestas foundation design, adjust the


adjusting legs so that the upper side of the
(not yet built-in) base flange is flush with the
upper side of the blinding layer outside the
centre part.

7 If it is not a Vestas foundation design, pre-


adjust the adjusting legs so that there is
sufficient space (minimum 150 mm) below
the base flange when you install the washers
and the nuts.
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12.2 To lift and to put the base flange segments in position 0011589000

Risk of suspended load failure! SPRA ID No. 19.01


• It is strictly prohibited to stay or work below a suspended load or in a drop zone.
The only exception to this rule is when you do approved work in a Vestas-defined
protective zone.
• Lifting operations are not allowed when the wind speed is higher than the maximum
value in accordance with the wind speed guidelines for the task. See the safety
regulations for the specific wind turbine.
• A lifting plan must be made and communicated to all personnel before the lifting
operation.
• Only trained and qualified service technicians and crane operators are allowed to
do the lifting operation.
• Make sure that an examination and test of the crane is done in accordance with
local requirements.
• Use only certified lifting equipment and fully examine the lifting equipment before it
is used.
• All hoists and lifting equipment must be formally examined before it is used.
• Obey the correct slinging arrangement and lifting procedures.
• Use the lifting equipment that is approved for the specific task.
• Use guiding ropes when situations are made dangerous by the rotation or
uncontrolled movement of a load.
• Obey the precautions to avoid entanglement when you attach or detach the load.

Risk of suspended load failure! SPRA ID No. 19.03


• Do not stay or work below a suspended load.
• Each guiding rope must be held by a service technician to control the movement of
the suspended load, if necessary.
• Guiding ropes must be actively held and monitored by service technicians during
the lifting operation. The guiding ropes may NOT be tied up to stationary, movable,
or other equivalent, uncontrolled equipment.
• Guiding rope service technicians must be clear of the drop zone.
• Locations for the guiding rope teams must be approved by the crane operator or
site supervisor.
• Guiding ropes can be wound to a maximum of 180° around a solid object. The solid
object must be smooth and free of possible rope entrapments that can prevent the
movement of the guiding rope.

1 Use a crane to lift the base flange segment.


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2 Install 3 swivel eye bolts (use the anchor bolt


holes) on the base flange segment at an
equal distance, and attach a sling or a chain
to the 3 swivel eye bolts.

3 Lift the base flange segment and put the


base flange segment onto the adjusting legs
in the designated location, and remove the 3
swivel eye bolts from the base flange
segment.

4 Do steps 1–3 to install the second, third, and fourth base flange segments on the adjusting
legs.

5 Attach the 4 anchor cage segments together


by the use of the bolts, washers, and nuts.
Make sure that there is no gap between the
4 anchor cage segments.

6 Adjust the adjusting legs to level the base


plate to the final position (the upper side of
the base flange is flush with the upper side of
the blinding layer outside the centre part).
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7 Make sure that all the adjusting legs (1) are


flush with the blinding layer (2).

12.3 To do a check of VUI numbers of anchor bolts, nuts, and washers 0011649743

The VUI numbers are used for traceability and must not be mixed up.
Write down all the VUI numbers in 0061-5845 ‘SIF for vertical assembly of the 2- and
4-segment anchor cage’.

1 Write down the assembly drawing number.

2 Write down the VUI numbers of the anchor bolt set. An anchor bolt set has anchor rods or
bolts, nuts, and washers. The components of the same set must have the same VUI
number.

3 Write down the VUI number of the base flange 1 segment.

4 Write down the VUI number of the base flange 2 segment.

5 Write down the VUI number of the base flange 3 segment.

6 Write down the VUI number of the base flange 4 segment.

7 Write down the VUI number of the LDF, if it is applicable.

8 Make sure that the anchor bolt sets used for a complete anchor cage have the same VUI
number.
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Anchor rods or bolts, nuts, and washers are supplier parts. These parts are
packed together in wooden boxes with the same VUI number on each wooden
box.

Figure 12.1: VUI number on the wooden box

12.4 To prepare the anchor bolts for vertical assembly 0011538790

1 Find the distance between the lower end of


anchor bolt and the top side of base flange in
the anchor cage assembly drawing.

The distance between the lower end of anchor bolt and the top side of base
flange is specified in the site assembly drawing.

a As an alternative, find the distance between the lower end of anchor bolts and the
bottom side of base flange in the anchor cage approval drawing.

2 Before the preparation of all anchor bolts, compare the space below the base flange with
the distance found in step 1 to make sure that there is sufficient space below the base
flange to install the washers and nuts.

3 Put all anchor bolts in the horizontal position on a support (for example, 3 equal distance
pieces of wood or equivalent soft material).
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4 Install all (counter) nuts and washers at the


bottom end of anchor bolt at the distance
found in step 1.

When you install the nuts and


counternuts, the washers must
be installed with the chamfered
edge against the nuts.

The bottom side of anchor bolt is identified by the difference in the thread length
at the top and bottom of the anchor bolt.

The counternut is installed on the top of base flange. The space must be
adjusted according to the base flange thickness.

12.5 To install the distance pipes together with anchor bolts 0011538789

1 Do a check of the position of the distance pipes in the anchor cage assembly drawing and
make a mark for the position of the distance pipes on the base flange.

2 Move the anchor bolts carefully through the


distance pipes. Be careful not to damage the
plastic coating/PE shrink hoses of the
anchor bolts.
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3 Vertically put the distance pipes together


with the anchor bolts in the designated
position through the base flange holes.

4 Make sure that the distance pipes are in the correct position and do not fall during
installation.

5 After you insert the anchor bolts through the


base flange holes, install the washers and
nuts at the bottom side of base flange.

When you install the nuts and


counternuts, the washers must
be installed with the chamfered
edge against the nuts.

6 Adjust the position of the nut pairs (nuts


below and above the base flange) to the
specified distance between the lower end of
the anchor bolts and the bottom side of the
base flange (found in step 1 of section 12.4
To prepare the anchor bolts for vertical
assembly, page 14) so that the nuts are flush
with the base flange.
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7 Do a check to see if the overarching


condition for the nuts below the base flange
is met.

a Make sure that the distance between the lower end of anchor bolts and the bottom
side of nuts is equal to 1 pitch of thread as a minimum.

8 Torque the nuts of the anchor bolts in the distance pipes below the base flange to 200 Nm.

a Use a pipe wrench to hold the


counternuts above the base flange in
position when you tighten the base
flange nuts.

9 Tighten the nuts above the base flange by hand.


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12.6 To install the remaining anchor bolts vertically 0011538788

1 Put all the remaining anchor bolts vertically


together with the nuts and washers into the
base flange holes between the installed
distance pipes.

2 Install the nuts and washers at the bottom


side of the base flange. Do not tighten the
nuts so that the installation of the template
flange is easy.

If the anchor bolts are not


tightened, the anchor bolts can
be adjusted so that the
installation of the template flange
at the top of anchor cage is easy.

3 Do steps 1 and 2 to install the remaining


anchor bolts in the base flange.
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12.7 To get access to the top of the anchor cage 0011538787

Risk of fall to the ground! SPRA ID No. 1.05


• It is only permitted to use man baskets and lifts made for personnel use.
• The mobile platform must be stable on the ground.
• Service technicians who do work from a mobile platform or man baskets must
wear personal fall arrest equipment.
• Obey the supplier instructions for the mobile platform.
• Platforms must have full-edge protection.
• Make sure that guard rails and toe boards are in position.
• Examine the personal fall arrest equipment before use to make sure that it is in
good condition.
• Use the necessary PPE that is given in PPE sheet 8.
• Use work positioning rope and fall arrest lanyard in combination to restrict
movement.
• The wind turbine must be locked to avoid all movement, if the mobile platform or
man basket will be in the wind turbine’s area of movement.
• Use a guiding rope to maintain the position of the man basket.

1 Use a man basket for a telescopic loader or


a forklift to get access to the top of the
anchor cage for the installation of the foam
blocks, the template flange, and the
fishplates or install the scaffolding around
the anchor cage to get access to the top of
the anchor cage.

12.8 To install the foam blocks 0011538786

1 Install the foam block on top of the first


distance pipe nearest to where the anchor
cage is divided into segments.
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2 Count the holes of the foam block and identify the holes that align with the position of the
first distance pipe of the anchor cage segment.

3 Slide the foam block down as far as possible


until it is secured tightly on the first distance
pipe.

4 Put the loose distance pipe from the top of


the foam block onto the anchor bolts that go
through the distance pipes.

5 Install the remaining foam blocks and loose distance pipes onto the anchor bolts.

6 Do a check of the position of the foam


blocks. See anchor cage assembly drawing.
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12.9 To install the template flange 0011589666

1 Attach the shackles to the lifting points on


the top side of the template flange segments,
and attach the chains or slings to the
shackles.

The top side of the template


flange segment is wider than the
bottom side.

2 Use a crane to lift the template flange segment.

3 Use a guiding rope for the installation of the template flange segment.

4 Lift the template flange segment to the top of


anchor bolts. Hold the template flange
segment in an inclined position for easy
installation.

5 Put the fully installed anchor bolts, which


were installed with the distance pipes,
through the holes in the template flange
segment.

6 Put the template flange segment onto the loose distance pipes and remove the lifting
equipment.
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7 Do steps 1–6 to install the second, third, and


fourth template flange segments.

8 Make sure that the foam blocks are flush


with the template flange, and attach the foam
blocks to the template flange by the use of a
duct tape.

9 Install the 3 tags with VUI number labels as given in section 12.10 To attach tags with VUI
numbers, page 24.

10 Put all the washers and nuts in the correct position on the top of template flange.

a If the anchor cage has LDF, install the


short distance pipes on each anchor
bolt on the top of template flange
before the installation of the washers
and nuts.
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11 Tighten all the nuts above the template


flange (or above the short distance pipes if
the anchor cage has LDF) only by hand to
prevent deflection of the template flange.

a Use a pipe wrench to hold the anchor bolts in position when you tighten the nuts.

b Tighten the nuts of the anchor bolts in the distance pipes first.

12 Measure the distance between the 4


template flange segments. Make sure that
the distance is not more than 2 mm from the
level.

13 Do a check to see if the distance between


the end of anchor bolt and the top of
template flange is the same as specified in
the anchor cage assembly drawing or
anchor cage approval drawing.
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12.10 To attach tags with VUI numbers 0011538785

1 Install the first tag with the VUI number of the anchor bolt set below the nut of the template
flange.

2 Install the second tag with the VUI number of the base flange below the nut of the template
flange. The VUI number and the number on the base flange must be the same.

3 Install the third tag with the VUI number (named A, B, C, or D) of the assembled anchor
cage embedment below the nut of the template flange.

Figure 12.2: Attach the tags with the VUI number

1 VUI number of anchor bolt set 2 VUI number of flange segments


3 VUI number of the base flange

12.11 To install the fishplates 0011589665

1 Install the fishplates where the 4 anchor


cage segments are joined.

a If the anchor cage has LDF, install the fishplates above the nuts installed on the short
distance pipes.
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12.12 To tighten the remaining nuts at the base flange 0011538783

1 Torque all the remaining nuts of the anchor bolts between the distance pipes below the base
flange to 50 Nm so that the nuts are flush with the base flange.

a Use a pipe wrench to hold the


counternuts above the base flange in
position when you tighten the nuts
below the base flange.

2 Make sure that the distance between the lower end of anchor bolt and the bottom side of nut
is equal to 1 pitch of thread as a minimum.

12.13 To do a check of and adjust the alignment 0011538832

1 Make 6 diagonal measurements in different


directions from centre to centre of bolts in
the inner ring to do a check of circularity of
the assembled anchor cage.

a Make sure that the measurements are within ±3 mm of the target value.

If the tolerance mentioned in the assembly drawing is different, the value


mentioned in this document must only be used.
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b Note the measurements in 0061-5845 ‘SIF for vertical assembly of 2- and 4-segment
anchor cage’.

2 Do a check of the height measurement to


make sure that the measurement is in
compliance with the measurement and
tolerance specified in the assembly drawing.

The height measurement specified in the assembly drawing shows the distance
from the top of the base flange to the top level of the foam.

3 Do a check to make sure that the template


flange is level in 4 positions along the top of
the template flange.

a Make sure that the variation in the levels is maximum of ±4 mm from the horizontal
level.

12.14 To prepare the anchor cage for concreting 0011589664

1 Examine the plastic coating/PE shrink hoses of the anchor bolts for damage.
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2 If there is damage to the plastic coating/PE


shrink hoses, repair the damage with
adhesive tape (duct tape).

3 Install the 4 fixing tools above the fishplate


and attach all the 4 fixing tools together in
the centre by the use of M16 bolts.

4 Install foam pipes or PVC-P protection caps


on the threaded top part of the anchor bolts
to give protection to the anchor bolts against
the concrete.

a If you use foam pipes, use a twister tool to attach the foam pipes to the threaded top
part of the anchor bolts.

Risk of exposure to hazardous substances and mixtures, shuttering oil! SPRA


ID 2.02
• Use the necessary PPE that is given in sheet G. Read and obey the related SDS.

5 Spray shuttering oil on the foam blocks and the vertical surface of the template flange for
easy removal.
Vertical assembly and installation of 4-segment anchor cage
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12.15 To prepare the anchor cage foundation for the handover 0011649744

1 Make sure that the concrete is sufficiently cured before you remove the template flange.

2 Do a check to make sure that the concrete


(1) and the anchor cage template flange (2)
are at the same level.

3 If it is necessary, clean the thread of anchor bolts before you loosen the nuts.

4 Loosen the nuts with a hand tool and use a pipe wrench to hold the anchor bolts in position
when you loosen the nuts.

Risk of exposure to a noise level above 80 dB(A) or tool vibrations! SPRA ID


No. 9.03
• Use the necessary PPE that is given in PPE sheet 10.
• Maintain the tools as given in the user manual.
• Examine the noise level in the user manual for the tool.

5 Use an electrical impact gun to fully loosen


the nuts (2). Make sure that the anchor bolt
(1) does not turn when you loosen the nut.

a If the anchor bolt starts to turn, stop the use of the electrical impact gun.
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b Turn the anchor bolt back into the original position, and use a hand tool to fully loosen
the nut.

c If the anchor bolt is loosened and it is not possible to turn it back into the original
position, contact the local WTG Engineering and Servicing for support.

Risk of suspended load failure! SPRA ID No. 19.02


• It is strictly prohibited to stay or work below a suspended load or in a drop zone.
The only exception to this rule is when you do approved work in a Vestas-defined
protective zone.

The template flange along with other tools must be returned when the procedure is
complete.

6 Lift and guide the template flange (1) in the


vertical direction to prevent damage to the
anchor bolts.

7 Loosen and remove the foam blocks from around the anchor bolts.

a Loosen the foam blocks (1).


Vertical assembly and installation of 4-segment anchor cage
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b Remove the foam blocks (1).

8 Remove the loose distance pipes from the anchor bolts.

9 Seal the anchor bolts that go through the


distance pipes with duct tape (1) so that the
water and grout do not flow into the distance
pipes.

10 Remove the concrete residue (1) from the


anchor bolts.
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11 Remove the foam residue (1) on the sides.

12 Clean the trench for foam remains, debris, shuttering oil, and other unwanted substances,
and remove loose particles.

a Use a water pressure jet (1) and


subsequent water vacuum pumping/
cleaning to clean the trench.

b Make sure that the anchor bolt heads are not damaged and contaminated during
cleaning.

13 Remove water from the trench with a


vacuum cleaner (1).
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Risk of exposure to hazardous substances and mixtures Non Naphtha! SPRA


ID No. 2.02
• Use the necessary PPE that is given in sheet G. Read and obey the related SDS.

14 Lubricate the head areas of the anchor bolts with corrosion inhibitor Non-Naphtha during the
construction phase until the tower installation starts.

15 Give protection to the foundation pedestal and its trench and, in particular, the head areas of
the anchor bolts against environmental influences and corrosion.

16 Put a tarpaulin onto the foundation.

17 Fill in 0061-5845 ‘SIF for vertical assembly of 2- and 4-segment anchor cage’ and upload it
to the VDB.

12.16 To prepare the anchor cage foundation for the T-flange tower
installation 0022039255

1 See 0035-2811 ‘Installation of towers’ and 0060-6511 ‘Installation of LDST split tower
sections’ for preparation of the anchor cage foundation for the T-flange tower installation.

2 If the anchor cage has LDF, see 0045-8646 ‘Levelling of load distribution flange’ (Mk 2C)
and 0083-1032 ‘Levelling of load distribution flange’ (Mk 3E) for the installation and levelling
of LDF for different types of tower.

12.17 To do the grouting and the final tensioning of the anchor cage
foundation 0011541674

1 See ‘Grouting of the anchor cage’ document in reference documents section to grout the
anchor cage foundation.
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2 See ‘Final tensioning of foundation anchor bolts’ document in reference documents section
for final tensioning of the foundation anchor bolts.

12.18 To use the template flange again 0025372484

1 Do a check according to 0061-5845 ‘SIF for vertical assembly of 2- and 4-segment anchor
cage’ to use the template flange again.