Testing Xelcor together with Bochum University of Applied Sciences
As offshore wind turbines continue to grow in size, the demands placed on safe and durable connection systems increase significantly. Xelcor is a newly developed foundation connection system based on high-performance polyurethane (PU) that meets these exact challenges. Together with Bochum University of Applied Sciences, the system was extensively tested using specially manufactured specimens – a demonstration of Rosenxt’s strong and active link to the scientific community.
Xelcor is an innovative, passively locking connection system for XXL offshore wind turbines, based on high-performance PU. In this so-called slip-joint connection, two conical steel components – typically of a monopile and a transition piece, or even of segmented monopiles – are securely joined using specially engineered PU elements. These PU components are bonded into the steel structure with advanced adhesive systems, creating a robust, load-transferring connection.
To systematically validate the design criteria and load-bearing capacity of the connection, extensive testing was carried out. The composite structure of steel, anti-corrosion coating, adhesive, and high-performance PU was examined in detail at the Laboratory for Building Materials and Structural Engineering at Bochum University of Applied Sciences.
At the blue mamBO test facility, experiments were performed on purpose-built 1:4 scale specimens. A specially designed test setup enabled the simultaneous application of compressive and shear forces, providing highly realistic offshore loading scenarios.
150 Test Specimens – Loads up to 2.5 MN
The test campaign included more than 150 specimens, on which the load-bearing capacity of the connection system was experimentally determined. Loads of up to 2.5 MN were applied. Preliminary tactile and functional tests had already confirmed the suitability of the test setup and the reliability of the manufacturing process.
The promising results now feed directly into the next phase of development. They allow for a precise and targeted design of the Xelcor connection for future offshore wind projects – and they strengthen our ambition to deliver safe, efficient, and sustainable solutions for critical infrastructure.
Our sincere thanks go to Bochum University of Applied Sciences and the team at the blue mamBO test facility for their excellent collaboration, precise testing campaigns, and valuable scientific exchange. At Rosenxt, technology and science go hand in hand. This close cooperation is a key driver in advancing innovative solutions like Xelcor safely, efficiently, and with a clear vision for the future.