SKYLIFT
The main objective of the project is to develop an installation system for wind turbines (SKYLIFT) fully compatible with a wide range of standard tubular towers used in the wind industry. This system enables the efficient and safe assembly of complete wind turbines at previously unreachable heights, without the need for high-tonnage auxiliary cranes.
Technical Objectives:
Greater wind resistance: Achieve structural wind resistance of up to 15 m/s, compared to the 12 m/s limit of conventional cranes.
Greater assembly efficiency: Conventional cranes operate under 30% of weather conditions, but SKYLIFT extends this window to 70%, doubling the available assembly time and generating significant time and cost savings.
Adaptability: The system must demonstrate the ability to adapt to various heights and diameters of standard tubular towers.
High load capacity: The assembly system will operate at ground level, meaning its load capacity will not be affected by the load moment, unlike conventional cranes.
Transportability: The new assembly system will require only 16 trucks, compared to the approximately 40 trucks needed to transport a large-scale crawler crane.
Low cost and high availability: The estimated price of the assembly system under development is €4 million—50 to 60% lower than the costs of current solutions on the market. Thanks to this cost advantage, it will experience greater market availability.
Suitable for all sites: The new assembly system overcomes access limitations to remote and hard-to-reach locations with high wind speeds, where assembly efficiency and adaptability to changing needs are crucial.
Nabrawind, Comansa, Tetrace, and Vors Control develop Skylift, an innovative system for crane-free installation of onshore wind turbines
July 31, Pamplona. The Navarre companies Nabrawind, Comansa, Tetrace, and Vors Control have developed Skylift, an innovative system for installing wind turbines without the need for cranes, even under extreme wind conditions. This pioneering solution, unique in the market, allows the complete installation of a wind turbine in just one week, opening up new possibilities for developing wind farms in remote or difficult-to-access locations.
This project has received support from the Government of Navarre through a grant co-financed by 40% from the European Regional Development Fund (ERDF), within the framework of the Operational Program ERDF 2021-2027 of Navarre. This subsidy has enabled progress on a solution that is unique in the market and holds significant potential for impacting the deployment of clean energy in complex environments.
A unique solution based on proven technology
The Skylift system is based on technology previously developed and tested by Nabrawind, which enables the erection of wind turbine towers without the involvement of large-capacity cranes. This new development expands the capabilities of the existing Nabralift technology, adapting it to conventional tubular towers and providing resistance against adverse weather conditions, such as winds of up to 15 m/s.
The system is compatible with any standard wind turbine model. Its primary strength lies in its ability to perform a complete installation in a short time and without dependence on heavy machinery, resulting in a significant reduction of costs, risks, and logistical constraints.
A system designed for demanding environments
Skylift is specifically designed to operate in areas with high wind speeds—such as green hydrogen parks or remote locations without access to an electrical grid—where conventional cranes cannot operate efficiently or safely. In these scenarios, the advantages of the system are amplified, enabling wind energy deployment in previously inaccessible locations.
A high-value collaborative development
Each company within the consortium has contributed key technological capabilities to Skylift’s development:
- Tetrace has led the structural design of key components for lifting: struts (upper elevation), radials (lower support), the AOS system (prevention of ovalization), as well as skidding systems for guiding sections. Additionally, it has defined the assembly processes and operational layouts with a focus on safety, precision, and efficiency.
- Comansa, traditionally focused on tower crane development, has successfully taken on the challenge of entering a new sector. This project has represented a strategic opportunity for the company to diversify its technical expertise and open new business lines.
- Vors Control has developed the dynamic physical model of the system, based on real equations and parameterized with operational data. Thanks to this model, structural equilibrium during lifting and balanced load distribution across platforms are ensured.
The technology developed under the Skylift project not only addresses current challenges in the onshore wind sector but also aligns with future market needs.
Project Video:
https://www.youtube.com/watch?v=aj0YHFZYv-Y
"This entity has received aid from the Government of Navarre, co-financed at 40% by the European Regional Development Fund through the ERDF 2021-2027 Operational Program of Navarre."
