Nowadays, wireless communication has become an essential part of networking for businesses, navigation systems, defense systems, and social services such as police, firefighters, and ambulances. Structural integrity of telecommunication towers is the key to ensure reliable communication; nonetheless, these structures are constantly under corrosion attack. In fact, underground corrosion is identified as one of the main causes for structural failure and collapse of telecom towers.
We provide the following services:
* GIS Corrosion Mapping and Drone Inspection and Thermographic Imaging for Tower Condition Assessment
* Paint Coating Selection for Above Ground and Underground Applications
* Custom-designed cathodic protection systems with deep well design for tower facilities
* Remaining Life Modeling and Estimation for Underground Assets
* Monopole Fatigue, Fatigue Sensor and Fatigue Mitigation
* Why stray current is an important issue in corrosion and How to detect it?
* Corrosion Engineering Training
Our condition assessment considers:
Inspection Overview and Procedures
The overall condition of the tower structural members, climbing facilities, fasteners, and other components are evaluated as outlined in this section. Visual and physical checks are performed to ensure that the tower and subsystems are structurally sound and functional.
Tower load bearing members , conduits, ladders, stairways. fasteners, and all load bering primary and secondary members will be checked, documented and severity of corrosion will be reported by our experienced climbers and NACE certified corrosion engineers. Corrosion mitigation: coating selection, surface preparation and application of coating per SSPC and NACE specifications will be provided for the Client’s review.
Physical inspections and UV thickness measurements are performed to determine steel member thickness using Ultrasonic Thickness Gauge. All corners of the towers are checked at the ground level and at any location that appears questionable with a three-point check that covers the leg and the braces on either side of it Coating thickness is also checked at these points using an Elcometer 456 Coating Thickness Gauge. ASTM A-123A is referenced for coating thickness requirements. Galvanized Thickness and protective organic coatings are measured as well.
Concrete foundations and anchoring hardware are visually checked for wear and damage.Concrete hardness tests are performed using Digital Concrete Test Hammer. Two hardness measurements are taken per foundation corner – one set of four readings on the top of the foundation (vertical reading) and one set of four readings on the side (horizontal reading).
MATERGENICS provides corrosion inspection/monitoring services, and corrosion risk assessment for different types of telecom structures including:
If corrosion is not detected and mitigated at its early stages, shortly it will lead to expensive refurbishment of corroded members, while in a longer time it can affect tower safety and increased risk for injuries, and fatalities. Periodic corrosion inspection and risk assessment is a cost-effective method to bring certainty to core asset safety. Team Matergenics can assist you on these tasks. At your request we can provide a comprehensive. presentation on our approach and experience in this important field
We can assist you with the following important tasks:
Team Matergenics is able to provide many unique services to assess the corrosion risk and to determine the remaining life of towers and anchors. We are also able to provide best-in-class CP design for helical anchors and special situations where installation of galvanic anodes is not feasible. What distinguishes us from our competition are the following:
Items 1, 3, 4, 5 and 6 are unique to team Matergenics and we do not know of any other firm performing these tasks. Please see the onsite photos attached to this document for examples of our work.
MATERGENICS’ corrosion inspection for telecom structure, involves three different stages:
Prior to site visits and field measurements, based on the project requirements, a desk study must performed to complete the following tasks:
Our NACE certified inspectors collect the key corrosion indicator data at tower base and anchor footings, and perform site-specific tests to characterize the service environment, including:
Collected samples during site visits must be examined in a controlled environment to identify:
All inspection findings and recommendations are included in a comprehensive report, that includes:
Engineering analysis and repair recommendations.
Matergenics is able to design, install, test, and monitor cathodic protection systems that prevent any further corrosion and extend the life of buried assets for at least 15 years. Compared to oil and gas industry, the tower industry as a whole is behind on implementation of CP method of extending in-service life of the assets. The oil and gas pipeline industry has been using this method successfully for many years to prevent failures and reduce inspection and maintenance costs.
PhD-level NACE-certified engineers in Matergenics have developed an advance simulation tool to design best-in-class anode bed designs for optimum protection of tower foundation regardless of structural materials and designs.
Matergenics offers innovative cathodic protection solutions to telecom utility companies. Our engineers and technicians are NACE certified professionals and use the latest technology to deliver best-in-class services to our clients.
Matergenics’ engineers and technicians are NACE certified experts in material selection, application, and inspection of coating system specific to below-grade and above-grade members of telecom towers.
We design and Install Cathodic Protection Systems for Tel-communication Towers Based on Corrosion Engineering Principles and By NACE Certified Technical Personnel.
We understand budget limitations and can provide options to fit your budget if you wish.
Another effective way to protect structures against corrosion attack is to use a coating film to shield it from the environment. However, not all coatings are created equally. Matergenics has several coating experts that are equipped to test and analyze coating quality based on common coating failure modes.
Proper coating system and Adequate surface preparation per SSPC and NACE standards are extremely important for atmospheric high elevation zones of the telecom tower. To improve the protection level at foundations of telecommunication structures, Matergenics recommends partial coating application along with CP system installation. This results in improved protection at both deep and shallow burials, also extends the lifespan of anodes. Answers to the following questions are keys for a successful coating application:
ASTM, SSPC, and NACE test procedures are followed to assure that the selected coating will survive and protect the structure as intended. These tests include:
Considering our expertise, Matergenics is the only company that can select coatings that work with cathodic protection systems to guarantee maximum protection to extend the life of any structure.
In the event of a failure, Matergenics is specially equipped to analyze fracture surfaces to determine the root cause. Matergenics has the capability to perform:
As a monument to Matergenics’ expertise and the belief that failures are a learning experience and should not be repeated, a Museum of Failure Analysis was created to showcase past studies. This museum even displays several corroded tower support structures that Matergenics has analyzed previously.
Matergenics offers training and educational seminars specifically designed and customized to meet the needs of individual clients on required, outcome-based learning. Seminars presenting fundamental topics are also available on subjects such as:
Seminars or presentations can be conducted onsite or at our location. The instructors include NACE-certified engineers, registered professional engineers, materials scientists and faculty, paint and coatings specialists, as well as cathodic protection specialists.
Our customization begins with identifying the audience, the appropriate scope and depth, and assessing the learning objectives. Next by learning about your assets and systems we can gear sessions to practical and relevant applications and utilize hands-on demonstrations to solidify the understanding of the topics.
Please call Dr, Zee at 412-952-9441 to dis the risk assessment and provide us with a description of the problem, and let us know how we can assist. Alternatively, you can send the]the tower information in the form to email@example.com.
We respond to all customers promptly by sending a proposal to address corrosion risk assessment and possible remedial/improvement methods and their costs. If we need more information, our engineers will contact you.
Looking forward to hearing from you!