Large-Scale Wind Tower Manufacturing
As the global renewable energy sector scales up, the demand for massive, high-integrity wind turbine structures continues to grow. These colossal structures face extreme dynamic loads, high winds, and highly corrosive offshore environments, making fabrication precision an absolute necessity.
Openex specializes in the heavy steel fabrication of tubular wind towers, monopiles, transition pieces, and floating foundations for both onshore and offshore wind farms. With 180 acres of facility space, exceptionally heavy plate rolling machines, and 250-ton lifting capacities, we are uniquely equipped to manufacture the massive "cans" and conical sections that make up modern megawatt-class wind turbines.
Wind Tower Manufacturing Specifications
We custom roll, weld, and coat wind tower sections to exacting OEM blueprints and international offshore standards.
| Maximum Diameter | Up to 10,000 mm (10 Meters) for massive monopiles |
|---|---|
| Max Plate Rolling Thickness | Up to 150 mm (Cold Rolled) |
| Materials Processed | High-Strength Structural Steels (S355NL, S420, S460, EH36, DH36) |
| Welding Standards | Submerged Arc Welding (SAW), AWS D1.1, EN 1090-2 (EXC3/EXC4) |
| Surface Coating | Marine-grade C5-M compliant painting, thermal zinc spraying, steel grit blasting. |
Our Work: Tower Sections
The Manufacturing Process
High-strength steel plates are precision-cut via large-gantry plasma/laser cutters. Edges are milled and beveled to exact angles to ensure deep, flawless weld penetration.
Our massive 3-roll and 4-roll CNC bending machines form the flat steel plates into perfectly cylindrical or conical "cans," ensuring zero flat spots on the leading edges.
Longitudinal and circumferential seams are welded using automated Submerged Arc Welding (SAW). Forged steel flanges are then fitted and welded to the ends of each section for tower stacking.
100% Ultrasonic Testing (UT) and Radiographic Testing (RT) is performed on all welds. The sections are then transferred to our massive blast booths for grit blasting and multi-layer offshore marine coating.