Hole patterns are common in engineering design for connections and/or assembly purposes. Geometrical discontinuities can cause stress concentration in localized areas, making them more prone to fatigue crack initiation and influencing the fatigue life of the overall unit. In the past, much effort has been exerted on fatigue modelling of holed plates from both experimental and theoretical perspectives. However, most studied objects were aluminium or titanium thin plates for aviation purposes. In this work, the fatigue performance of a downscaled holed thick steel plate, extracted from a novel C1 Wedge Connection for wind turbine tower assembling, was tested and categorized according to commonly used industry codes. In particular, the influence of the surface size effect was experimentally observed and computationally discussed. Finally, a probabilistic fatigue model was proposed, which gives a favourable prediction on the fatigue behaviour of the surface polished holed thick steel plate with the help of the Smith–Watson–Topper (SWT) model.

This paper shows a part of the analysis of the development of the second generation of the C1 wedge connections for use in offshore wind turbine supporting towers. The novelty of this connection is that bolt failure is avoided under static and fatigue loads. This study aims to investigate the tensile behaviour of the connection by combining the findings of experiments and finite element (FE) analysis. Two specimens subjected to uniaxial and cyclic tensile loading tested until failure are used for illustration. Advanced quasi-static FE analysis results, considering the most detailed geometry and using an explicit dynamic solver, are compared to the experimental results. The FE analysis results agree well with the experimental results. Based on the FE model, a parametric study is carried out to analyse the influence of the bolt grade, friction coefficient between contact surfaces, and preloading force level on mechanical behaviour. Failure modes, bolt force development, and the evolution of gap opening between contacted segments are analysed. Results demonstrate that the tensile fracture of the C1 wedge connection mainly appears in the lower segment. All the investigated parameters have a negligible effect on the connection's ultimate resistance and failure mode. However, the friction coefficient between contact surfaces and bolt preload level significantly affects the connection's local deformation capacity and the response of the bolt stress range. The FE simulation provides practical guidance for designing this connection without bolt failure.

Increasing loads on the connections of tubular towers that support wind turbines are making the traditional bolted L-flange more challenging to design, while the large mass of components and tools make installation challenging from a safety perspective. The C1 Wedge Connection is a symmetrical connection between tubular sections. The connection consists of a cylindrical lower flange and a fork-shaped upper flange that slides over the lower flange. Both flanges have radial elongated holes distributed along the perimeter allowing the C1 fasteners to pull the two flanges together. The fastener assembly of the C1 Wedge Connection uses a small, horizontally placed bolt to pull two wedges together. The wedges transform and magnify the horizontal bolt force into a larger preload between the flanges by pulling them together. The orientation of the bolt in the fastener prevents significant load fluctuations under external loading. As a result, unlike a bolted L-flange, the C1 Wedge Connection is less susceptible to preload loss, thereby eliminating the need for regular maintenance and inspection. The scalability of the C1 Wedge Connection makes it suitable for larger loads. These larger loads are expected with increasing size of wind turbines and when connections are used in more demanding locations such as hurricane and seismic conditions or where connections are subjected to high dynamic loads caused by extreme wave conditions or on floating foundations.