Industries

Wind power towers and monopiles serve as the foundation that supports massive wind turbines securely at high elevations. The tower is the column that supports the turbine from the ground, while the monopile is the base structure driven into the seabed for offshore wind power generation.

When processing heavy steel materials to manufacture towers and monopiles, Crosby IP Clamps play a vital role in securely holding the steel. The optimal clamp can be selected according to the strength and characteristics of the material.

IPU10H is ideal for lifting hard steel from a horizontal to a vertical position. IPHGUZ is suitable for moving relatively thin steel plates horizontally, and IPNM10 uses polyurethane pads to grip the steel, making it perfect for handling stainless steel or painted steel where preventing surface damage is essential.

Products Used:

Crosby IP Model IPU10H

Crosby IP IPHGUZ: Universal Lifting Eye

Crosby IP Model IPNM10

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When moving a completed monopile inside the factory using a crane, Crosby G-2130 Bolt Type Shackles are used to secure the fiber slings wrapped directly around the monopile.

These shackles have passed rigorous fatigue and Charpy impact tests and feature high corrosion resistance thanks to galvanization. With an industry-leading safety factor of 6:1, they ensure safe and continuous use even in the most demanding manufacturing environments.

Products Used:

Crosby G-2130 / S-2130 Bolt Type Anchor Shackles

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Wind turbine blades are extremely large, often exceeding 50 meters in length, and require specialized vehicles for transport. During transportation, if excessive or uneven loads are applied to specific points on the vehicle, the blade may fall, posing a serious risk of accidents. Therefore, accurate blade load measurement is critically important.

Radiolink Plus offers a comprehensive lineup with capacities up to 300 tons and features IP67-rated dust and water protection. By installing multiple units on the platform securing the blade, loads and center of gravity can be monitored wirelessly and in real time via a dedicated app—up to 100 meters away (or up to 1,000 meters when using Handheld Plus). This capability helps prevent accidents and ensures safe, reliable transportation.

Products Used:

Crosby Straightpoint Radiolink Plus (RLP)

LB Lever Hoist is ideal for load securing operations thanks to its unique freewheel mechanism, which allows safe and quick adjustment of chain length.

In addition, its original high-strength nickel-plated chain offers excellent resistance to rust and wear, while the lightweight, compact, yet robust body ensures safe and efficient transportation of large, heavy components such as blades.

Please note: In some regions (such as North America and Europe), the use of lever hoists for load securing may not be permitted. If you are unsure, please contact us for clarification.

Products Used:

Kito LB Lever Hoist

Traditional load binders require manual tightening, which can be time-consuming when securing multiple points on large components such as blades and towers.

Speedbinders allow you to quickly secure loads using a power drill, significantly reducing the time needed for tightening and releasing. Moreover, even if a power drill becomes unavailable, the binder can still be released using standard tools such as a wrench, ensuring peace of mind.

Products Used:

Speedbinders TD-66, TD-92, TD-13

Tower installation is a critical process that forms the foundation of wind power generation. The tower’s role is to position the wind turbine at a high elevation to capture stronger and more stable winds. On-site, towers that extend for tens of meters are divided into multiple sections for transport and then assembled one segment at a time with precision using specialized cranes.

Crosby G-2130 Bolt Type Shackles play an essential role in tower installation. Featuring high corrosion resistance through galvanization, they have passed rigorous fatigue and Charpy impact tests. Ideal for harsh outdoor environments, they provide industry-leading safety with a 6:1 design factor, ensuring secure lifting of heavy towers.

Crosby McKissick M-491 / G-491 Tower/Derrick Hoist Blocks are specifically designed for wind turbine towers. Equipped with sealed tapered roller bearings, they enable high-speed wire rope movement. This ensures proper load distribution and allows safe, efficient installation when lifting long tower sections with mobile cranes.

Products Used:

Crosby G-2130 / S-2130 Bolt Type Anchor Shackles

Crosby McKissick M-491 / G-491 Tower/Derrick Hoist Blocks

Project Gallery:

https://youtu.be/95uHcaEtQq0?si=tVLRUuaUDksTo-pm

Blades are highly susceptible to wind, so installation must be carried out with great care while monitoring wind speed and weather conditions. Even a slight deviation in the mounting angle or balance can reduce power generation efficiency or cause long-term issues, making advanced technical expertise and strict safety management at height essential.

For blades measuring up to 60–80 meters in length, Airpes clamp systems enable precise balance adjustments by measuring the center of gravity and using hydraulic adjustment tools. This ensures that even hazardous installation tasks can be performed safely and efficiently.

When combined with the dedicated service kit, telemeters and cameras accurately measure the distance between the hub and the clamp, allowing operators to continuously identify the blade’s center of gravity—even at height—and carry out installation safely. The service kit includes a camera, a telemeter for measuring the distance from the ground to the turbine or blade, and a Data Feedback (DFB) display for remotely monitoring the clamp’s safety parameters.

Products Used:

Crosby Airpes Yoke Clamp

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For the installation of relatively small blades, LB Lever Hoist demonstrates its true value. Its lightweight and compact design makes handling easy, while the unique freewheel mechanism allows for quick and safe chain length adjustment.

By using two units together, precise alignment of the blade can be achieved smoothly, ensuring efficient and reliable installation work.

Products Used:

Kito LB Lever Hoists

Integrated hub blades are assembled on the ground by combining three blades with the hub to create a complete rotor unit, which is then installed at the top of the wind turbine in one lift.

Working at ground level allows for safer and more precise assembly; however, lifting such a massive structure—often weighing tens of tons—requires advanced operational skills, as it is highly susceptible to wind conditions.

380 Series Hook Blocks are available in capacities up to 300 tons. By guiding the crane’s wire rope through the sheaves, they help distribute the load and reduce rope wear, ensuring safe and efficient installation of integrated hub blades.

Products Used:

380 Series Hook Blocks

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For offshore wind projects involving monopile installation, it is essential to select products that not only offer durability in lifting gear but also account for corrosion caused by seawater.

Crosby G-2130 Bolt Type Shackles feature high corrosion resistance thanks to galvanization, making them ideal for monopile installation work. They have passed rigorous fatigue and Charpy impact tests and deliver reliable lifting performance even in harsh offshore environments, backed by the industry-leading safety factor of 6:1.

G-2160 Wide Body Shackles are available in capacities up to 300 tons, and their zinc-coated bodies are perfectly suited for handling heavy monopiles during installation.

Products Used:

Crosby G-2130 / S-2130 Bolt Type Anchor Shackles

Crosby G-2160 Wide Body Shackles

Project Gallery:

https://www.youtube.com/watch?v=6DEilbQhZIo

Electricity generated by offshore wind turbines is transmitted to land through subsea cables. The installation of these cables relies on ROVs (Remotely Operated Vehicles), and Kito Crosby offers a range of shackles specifically designed for ROV applications.

Gunnebo Industries ROV Retrieve Shackle No.861 is available in capacities from 12 to 55 tons and features superior corrosion resistance thanks to its hot-dip galvanized coating. With no loose components such as wires or monkey fists, there is no risk of parts snagging during operation.

In addition, the indicator allows for quick visual confirmation of pin open/close status, while the V-shaped handle is optimized for ROV handling. The combination of a spring-loaded locking mechanism and a bolt-secured pin provides a dual safety system, ensuring reliable performance even in harsh underwater conditions.

Products Used:

Gunnebo Industries ROV Retrieve Shackle No 861

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Offshore wind projects are significantly affected by ocean currents and environmental conditions. Accurate load data for monitoring during lifting operations and maintenance is essential to ensure safety at the worksite.

SubseaLink is designed specifically for use underwater and on the seabed. Its stainless steel body withstands seawater, temperature fluctuations, and water pressure at depths of up to 2,000 meters, while delivering precise load measurements. It is also engineered to fit all Kito Crosby ROV shackles.

Products Used:

Crosby Straightpoint SubseaLink

Floating offshore wind power involves installing wind turbines on floating structures, enabling power generation in deep-water areas where fixed-bottom foundations are not feasible. This approach allows the use of stable winds in vast ocean regions that were previously inaccessible, significantly contributing to increased energy output.

However, floating wind turbines are constantly exposed to waves, wind, and currents, creating a risk of drifting. A robust mooring system is therefore essential.

Crosby Feubo HFL NDur Link plays a key role in these mooring systems. Developed at a state-of-the-art research facility in Hattingen, Germany, where extreme marine conditions are simulated, this product offers ten times the fatigue life of conventional solutions. It is certified by leading classification societies, including DNV, LROS, and ABS, ensuring exceptional reliability.

Products Used:

Crosby Feubo HFL NDur Link

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Electricity generated by wind turbines fluctuates in voltage and frequency due to changes in wind speed. A PCS (Power Conditioning System) adjusts these parameters so that the power can be accepted by the utility grid. In offshore wind projects, PCS units are typically installed at the base inside the tower, together with an ACB (Air Circuit Breaker), a high-capacity breaker that protects equipment from overloads and short circuits.

At a floating offshore wind farm in Nagasaki, Japan, the PCS was first pulled inside the tower using CB chain hoists, then positioned at the base with a 7.5-ton ER2 electric chain hoist. ER2 features a highly reliable electromagnetic brake and a proprietary nickel-plated chain that resists rust and wear, ensuring durability even in harsh marine environments.

After installing the PCS and ACB, ER2 and CBs were removed and continued to play a key role in the installation of multiple offshore wind turbines.

Products Used:

Kito ER2 Electric Chain Hoists

Kito CB Manual Chain Hoists

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The nacelle is the machinery room located at the top of the wind turbine, housing critical components such as the generator, gearbox, and control systems. Maintenance inside the nacelle includes checking and replacing worn gears and bearings, changing lubricating oil, inspecting electrical systems, and cleaning and adjusting cooling equipment.

By installing ER2W (a wind-power-specific version of ER2 electric chain hoist) on the yaw deck directly beneath the nacelle, component replacement work inside the nacelle can be carried out more efficiently. ER2W is a specialized model that achieves approximately 1.5 times the lifting speed of the standard ER2, enabling safe and efficient maintenance operations even at nacelles located more than 100 meters above ground.

Products Used:

Kito ER2 Electric Chain Hoists

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In wind power generation, transformers play a crucial role in converting the voltage to an appropriate level so that electricity generated by the wind turbine can be transmitted to the power grid. In many turbines, these transformers are installed inside the nacelle, where they are exposed to heat and vibration from long hours of operation, making regular inspection and replacement essential.

At a wind turbine in Ukraine, the nacelle was designed with an opening mechanism that allows transformers to be moved in and out directly. By using two ER2 5-ton electric chain hoists equipped with inverters, vibration of large transformers can be minimized and positioning accuracy improved, enabling safe and efficient replacement work.

In addition, the installation of the support frames for transformer replacement was carried out using the highly reliable LB lever hoists, which combine lightweight, compact design with exceptional durability.

Products Used:

Kito ER2 Electric Chain Hoists

Kito LB Lever Hoists

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In wind power generation, pitch motors inside the hub instantly adjust the blade angle according to wind strength to maintain optimal power output. If a pitch motor deteriorates or fails, blade angle control becomes impossible, which can lead not only to reduced output but also to the inability to safely stop the turbine during strong winds.

ED electric chain hoist is ideal for pitch motor replacement work. Compact and easy to carry, the ED is perfectly suited for the limited space inside the hub. Its fast lifting and lowering speed allows quick replacement when combined with a small jib crane. In addition, its unique nickel-plated chain is highly resistant to rust and wear, making it well-suited for maintenance work on wind turbines located along coastlines.

Crosby HG-226 Eye & Eye Turnbuckles were used to secure the small jib crane. The zinc-coated body offers excellent corrosion resistance and has passed 20,000 fatigue tests. In addition, it meets the ASME B30.26 standards, making it an ideal product for long-term maintenance operations.

Products Used:

Kito ED Electric Chain Hoists

Crosby HG-226 Eye & Eye

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Crosby G-2130 Bolt Type Shackles feature superior corrosion resistance thanks to their galvanized finish. They have passed rigorous fatigue and Charpy impact tests and deliver an industry-leading safety factor of 6:1.

This ensures secure handling of blades, nacelles, and towers weighing tens of tons, contributing to safe and efficient dismantling operations.

Products Used:

Crosby G-2130 / S-2130 Bolt Type Anchor Shackles

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