SpanSet Axzion, a manufacturer of lifting equipment, has aligned its growth with the expansion of the wind energy sector. Founded over 50 years ago, SpanSet started as a modest operation. Sven Lehmann, Managing Director of SpanSet Axzion Germany, a SpanSet division, recalls how the company started in a shed.
Sven said that with the wind industry’s expansion, crane technology evolved rapidly, leading to advancements in lifting equipment.
“The size of the cranes was increasing, and the lifting equipment had to keep up,” he said.
Initially, wind turbines of about two megawatts demanded cranes capable of lifting 70 to 75 tonnes (t) at approximately 100 metres (m) height. As turbines increased to three megawatts (MW) and beyond, the complexity of lifts escalated, leading to SpanSet developing specialised equipment such as the Vario TAPs and J-hooks. Today, all SpanSet Axzion products are available throughout Australia with local support from the company’s office in Sydney.
TAPs and J-Hooks
One early challenge was how to lift tower sections. A single section can weigh anywhere from 20 to 100 tonnes and must be hoisted vertically and bolted precisely to the section below it. A decade ago, it was common to see tower flanges (the rims of each segment) get bent or damaged during installation. The damage often occurred as sections were manoeuvred from horizontal (as delivered on a truck) to vertical; traditional lifting slings could put uneven pressure on the flange, warping the steel.
The solution was a Tower Tool Kit that spreads out the forces and adds control to the lift. Central to this kit are the Tower Attachment Points (TAPs) – clamp-like brackets that bolt into a tower segment’s flange holes to create secure lifting points. Sven said that unlike older custom brackets that were heavy and required a crane just to mount, SpanSet Axzion’s TAPs are compact (around 30 kilograms each) and can be attached by hand.
Each forged TAP bracket can bear about 25 tonnes, and multiple TAPs are used together so that even very large tower sections (flange diameters from 2.5 up to eight metres) can be lifted safely. By using four or more TAPs around the rim, the load is distributed evenly. The Vario TAPs now support a Working Load Limit (WLL) of up to 60 tonnes and are operational at temperatures as low as minus 20°C. A certified app will soon be available to optimise lifting setups for individual use cases.
Another key part of the tower kit is the Vario J-Hook, a J-shaped lifting hook designed specifically for upending tower sections. The J-Hook slips under the horizontal tower cylinder and grabs it at the flange, then pivots as the crane lifts, turning the section upright.
SpanSet Axzion’s engineers equipped the J-Hook with a patented inner sliding shell that glides as the load turns, preventing any one point on the flange from taking excessive pressure. A locking tab engages behind the flange to hold the segment securely during the tilt-up manoeuvre. The latest “Vario” J-Hooks come in capacities of 40, 60, 90, and 120 tonnes, adaptable to different section sizes. The 120-tonne Vario J-Hook notably supported the installation of one of the world’s highest flagpoles in Baku, Azerbaijan. The J-Hooks also allow remote release – once a tower segment is bolted in place, riggers can disengage the hook via cable or radio control, eliminating the need for a worker to climb up and unhook it by hand.
SpanSet packages the TAPs, J-Hook, slings and shackles into a “Tower Tool Kit” or repowering kit that wind farm crews can use not only for new construction but also for major component exchanges, such as replacing old tower sections or performing upgrades, years later. The Tower Tool Kit showcases the combination of Axzion and SpanSet products, including the well-integrated Magnum Force High Performance Round sling.
Nacelle Lifts
If the tower is the spine of a wind turbine, the nacelle is its heart and muscle. It is the box housing the generator, gearbox, and other vital machinery on top. Modern nacelles can weigh from 70 to 100 tonnes. Lifting a nacelle into place presents another engineering puzzle. Unlike a uniform tower section, a nacelle’s weight might be unevenly distributed. Aligning the centre of gravity was tricky using older methods. A slight imbalance could cause the nacelle to tilt or sway.
SpanSet Axzion addressed this with custom nacelle lifting beams that include adjustable suspension points and motorised levelling systems. Essentially, these lifting assemblies let crews fine-tune how the nacelle hangs while it’s already in the air.
Sven explained how the product managed to counteract the uneven weight. “You need the possibility to adjust the centre of gravity position. We developed tools allowing mechanical and hydraulic adjustments during the lift,” he said. “Such control ensures nacelles are accurately aligned and securely placed atop turbine towers.”
Similarly, the equipment to lift rotors has evolved. Early installations involved assembling rotors at ground level, lifting them entirely, and positioning them atop the nacelle, posing logistical challenges. Axzion responded with rotor lifting tools like the “banana” rotor lifting frame and, subsequently, other rotor tilting tools. Sven said these tools enabled safe vertical positioning of large rotor assemblies mid-air, which increased both speed and safety.
The Single Blade Installation (SBI) tool is another breakthrough in this regard. Initially, blades were lifted with rudimentary methods, including slings lubricated with grease – a risky procedure. SpanSet Axzion’s SBI tool introduced precise, secure handling of single blades. It incorporates hydraulic supports, adjustable pitch belts, and remote-controlled release mechanisms.
“Companies in the United States doing main component exchanges save significant cost by using SBI,” Sven said. “They completed blade exchanges at three turbines in one week, 18 lifts, nine up, nine down.”
Looking forward, SpanSet Axzion plans significant developments, particularly in offshore lifting technology, including ongoing efforts to develop an XXL-size offshore lifting tool, emphasising its broader implications.
“It’s not only about building a tool but developing test methods and stands to meet future offshore lifting requirements,” Sven said.
Additionally, SpanSet Axzion is exploring digital solutions, including camera-assisted load management systems and remote-control capabilities.
Sven said SpanSet’s strategy is to integrate collaboration with technology to enhance the overall product.
“It’s about having intelligent lifting tools that help you see and control the load remotely,” he said. “We cannot develop everything ourselves; we are ready to integrate solutions. Sharing developments is sometimes better.”
