Improving Surge Bin Ultrasonic Testing with the UT Pole

Surge bin ultrasonic testing is critical for maintaining asset integrity in mining operations. These high-impact structures handle constant material flow, making them highly susceptible to wear, deformation, and wall loss.

Ensuring accurate thickness data in these environments is essential, but traditional rope access ultrasonic testing methods introduce variability, increased inspection time, and operator fatigue.

The challenge with traditional rope access UT

Rope access ultrasonic testing has been widely used for vertical steel structures, but it introduces several practical limitations that affect data quality and efficiency.

Inconsistent probe contact

Maintaining steady probe pressure while suspended on ropes is difficult. Small variations in contact can lead to inconsistent readings and unreliable data.

Coupling challenges

Achieving proper coupling on vertical or overhead surfaces is not always straightforward. Poor coupling reduces signal quality and increases the likelihood of rework.

Physical strain and inspection time

Extended time on ropes increases fatigue for technicians. This impacts productivity and can lead to longer inspection durations and additional safety considerations.

For a more in-depth look at how access methods impact inspection outcomes, crawler-based approaches are explored in crawler vs drone inspection technology.

A practical solution: the UT Pole

To address these challenges, Nexxis developed a tool designed to enhance inspector capability without changing established workflows.

The UT Pole is a lightweight, telescopic system that improves reach, stability, and measurement consistency during ultrasonic thickness inspections.

Designed for reach and stability

• 9 m telescopic carbon-fibre shaft enables access to elevated inspection points without repositioning
• Lightweight construction reduces operator fatigue during extended use

Consistent probe contact

• Spring-loaded gimbal mount maintains even pressure against the surface
• Improved contact stability supports repeatable and reliable measurements

Reliable coupling for accurate data

• Integrated water-coupling system ensures consistent signal transmission
• Reduces variability caused by manual coupling methods

Performance in surge bin inspections

During a recent surge bin inspection, the UT Pole delivered measurable improvements in both data quality and inspection efficiency.

Improved data consistency

• Uniform readings across all test points
• Reduced variability between measurements

Faster inspection workflows

• Fewer re-scans required due to improved first-pass accuracy
• Increased inspection speed without compromising data quality

Reduced operator fatigue

• Less physical strain compared to rope-based probe handling
• More controlled inspection process for technicians

Supporting inspectors with better tools

The UT Pole demonstrates a practical approach to inspection technology. Instead of replacing existing methods, it enhances them by improving stability, consistency, and usability.

This aligns with a broader trend in inspection technology, where solutions are designed to support inspectors in achieving better outcomes with reduced risk. Similar principles are applied in ultrasonic thickness inspection strategies, where access and repeatability are key to success.

Contact us to find out more about UT Pole, or any of our other ultrasonic thickness testing equipment, or request a quote online.