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EN 02–Wind-2-08/16 I © AXZION-GKS Stahl- und Maschinenbau GmbH, Deutschland, 2016

Inhalt

02.1 Tower 7 AXZION Pulley 8 Tower Attachment Point TAP 10 AXZION J-Hook 12 AXZION Vario J-Hook 12 Tower Errection 14 Complete Tower Gripper 16 02.2 Nacelle 18 Nacelle Spreader Beam 20

02.4 Special Tools 32 Transport Equipment 34 „China Hat“ Tower Covers 34 Axzion Rental 35 Repowering Set 35

02.5 Services 36 Maintenance, repairs and operation 38 24/7 service 38 Risk analysis and assessment 39

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The SpanSet group is the world specialist in lifting and securing loads.

With subsidiaries in all major developed countries and a global network of representatives, SpanSet is well versed in current regulations and can provide comprehensive on-site services.We manufacture a variety of products, from fibres and trusses, to ratchets, lashing straps, steel components and the lifting equipment itself.As a manufacturer, we are able to provide you with tailor-made equipment and customised solutions that fulfil the stringent requirements that must be met when transporting and assembling wind turbines and other large-scale components.

From wire rope to lifting slings, from ratchets to lashing straps, even from steel to load suspension equipment. We manufacture it all and, as such, we can provide you with custom-made designs and specialist solutions to the serious challenges which are part and parcel of the transportation and assembly of wind turbines.

A manufacturer is “responsible for designing and producing products” that are placed on the market bearing its name.

AXZION-GKS provides everything from one source. Development, manufacture and service are closely linked, any problems that may arise are resolved quickly and the design is tailored perfectly to the latest manufacturing techniques.

Certified Safety.

How we‘re ensuring todaythat our name will be valuedtomorrow.

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02. 1Tower

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AXZION Pulley

02.1 TOWER

AXZION PulleyThe new Axzion Pulleys can be used for lifting and turning of complete steel tower segments. Both, the use of steel wire ropes and SpanSet Magnum X round slings are possible. Designed with self-lubricating bearings. No maintainace needed.

The wire rope slings reinforced eyes stiffeners are suitable for continuous use with shackles. On the crane side, the turner rolls have robust Magnum round slings.

On request also with transport and storage rack.

Pulley

Technical details

Pulley WLL

PUL 4000 000 0 Pulley complete with sling, wirerope and shakles 40000 kgPUL 4000 000 1 Pulley complete with sling, MagnumX and shakles 40000 kgPUL 6000 000 1 Pulley complete with sling, MagnumX and shakles 60000 kgPUL 8000 000 1 Pulley complete with sling, MagnumX and shakles 80000 kgPUL 10000 000 1 Pulley complete with sling, MagnumX and shakles 100000 kg

crane-side with SpanSet Magnum Plus round slings which fits to each crane hook

With quality shackles

Self-lubricating bearings

Very easy to handle and very light: SpanSet Magnum X round sling.

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Tower Attachment Point TAP

02.1 TOWER

Tower Attachment Point TAPAXZION Vario TAPMore powerful systems, offshore use, increasin-gly heavier tower segments for wind turbines. The lift tabs developed in the past no longer fulfil their task; the standard three screws are no longer sufficient to guarantee the required bearing capacity.Bump plates with four or more individual holes need to be specially adapted to each threaded flange. These heavy mounting solutions can only be handled by a crane.

Installation teams for wind turbines need to lift and rotate the different tower segments. Conven-tional tower attachment points are not flexible enough and are clearly too heavy for installation on site. Several attachment points in in different sizes often need to be used for the different tower sizes.

The AXZION Vario TAP fits all system types. The extra-wide slots in combination with the slip-slide

Technical details

Vario Tower Attachement Point Dead weight WLL

TAP 1700 0000 0 Tower Attachment Point, TAP 20 kg 17000 kgTAP 2750 0000 0 Tower Attachment Point, TAP 30 kg 27500 kgTAP 4000 2000 0 Tower Attachment Point, TAP 30 kg 40000 kgTAP 6000 0000 0 Tower Attachment Point, TAP 50 kg 60000 kg

pressure plates with cross holes can be used to simulate different sized hole circumferences. The use of an auxiliary crane or a forklift for mounting is no longer required, as the weight of the Vario-TAP is a „portable“ 30 kg.

The TAP‘s carrying capacities of 17,000 kg, 27,500 kg or 40,000 kg can be easily recognised and distinguished by the shape. The input side is colour-coded and clearly labelled: RED = LEFT and RIGHT = GREEN. The extra-stable slip-slide pressure plates are available for all bolt sizes from M36 to M48*.

AXZION High Capacity TAP (60,000 kg)The strongest TAP in the Axzion TAP family. The TAP is bolted with five screws on the tower flange. The slip-slide pressure components are specially adapted for each tower flange. The TAP loop is used to connect the TAP to the Axzion Pulley and to lift and turn tower segments with a total weight of up to 240,000 kg.

Work load limit (WLL) isidentifiable in the form.

Axzion Vario TAP

Vario Pressure Unit (VPU)

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Vario-J-Hook

02.1 TOWER

J-HookVario-J-Hook

AXZION Vario J-Hook

The Vario J-Hook can be simply attached to the bottom flange in 12 o‘clock position of the tower segment. During the turning process, the robust adjustable counter bracket hooks behind the flange, and all contact surfaces are equipped with the robust secutex.

Significant time-saving: After the lifting / turning process, the Vario J-Hook can be easily removed by releasing it with a crane. Time-consuming assembly work is not required.

In contrast, securely fastened suspension points need to be disassembled after the turning process, which requires work to be carried out under the load. Work under a suspended load is absolutely impermissible. The load therefore needs to be placed on trestles, which significant-ly delays the process.

J-Hook WLL

JHO 4000 000 3 J-Hook [EN 13155 EU-Norm] 40000 kgJHO 4000 000 4 J-Hook [ASME US-Norm] 40000 kg

Vario J-Hook WLL

JHO 4000 000 1 Vario J-Hook [ASME US-Norm] 40000 kgJHO 6000 000 0 Vario J-Hook [EN 13155 EU-Norm] 60000 kgJHO 8000 000 1 Vario J-Hook [ASME US-Norm] 80000 kgJHO 10000 00 1 Vario J-Hook [ASME US-Norm] 140000 kg

Technical details

AXZION J-Hook

J-Hooks are designed for the horizontal transport of steel tower sections. The newly developed AXZION J-Hooks are extremely compact and feature round tubes with free running secutex pipe modules.

This means you can position the hook wherever you need on the flange, „rolling“ it into its 12 o‘clock position. The contact area at the back is also protected with secutex bufferpad, stopping the high quality flange from being scratched or buffeted.

J-Hook: For horizontal transport

Rotation joint with adjustable counter bracket for each tower flnages.

Bollard suspension forround slings.

Attachment points for tag lines.

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Tower ErrectionWith Pulley, TAP and Vario-J-Hook

02.1 TOWER

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Complete Tower Gripper

02.1 TOWER

Complete Tower GripperComplete Tower Gripper CTG for the vertical transport of assembled towers

„Time is money“, which is especially true in the offshore division. The costs of installation vessels are spectacularly high and the weather can change quickly. We have now drastically reduced construction times offshore by installing pre assembled towers.

First we lift the pre-assembled towers onboard with the new AXZION Complete Tower Gripper (patent pending) then install them later on the foundation in the wind park.

The grippers are purely mechanical, no need for an external power supply. This makes the AXZION Complete Tower Gripper (current capacities 300t, 450t, 650t) perfect for harsh offshore conditions.

It can be locked either manually or by remote con-trol. The gripper jaws are protected with secutex impact protection, stopping the towers‘ high quality flanges from being scratched or buffeted.

Options: JoJo system to align the gripper under load, large working platform, sea-lashing, remote control, camera system, ppe atachment points

PPE attachment piont.

Buffer pads equipped with secutex.

Working platform with camera system.

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02. 2Nacelle

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Nacelle Spreader Beam

02.2 NACELLE

Nacelle Spreader BeamThe largest and hardest-to-lift part of a wind turbine is the engine room or nacelle. Offshore or onshore, the loads are enormous and often push the assembly cranes to their limits. The large engine houses are almost impossible to control from the crane, and manual strength or tagline systems are no longer up to the task.

Because of the different configurations the COG of the nacelle is not always directly under the crane hook, and this tilts the load. AXZION nacel-le beams have an adjustable hook on the crane side, which you can choose to lock the load into.

Whether hydraulic cylinders or a spindle drive, with or without a built-in power supply, AXZION nacelle beams are perfect for any application. The load-side attachment points are adapted to the engine room, the round slings can be adjusted to fit, and the chance of causing expensive damage is eliminated.

Options: Parking feet, tagline points to align the beam under load, sea-lashing, diesel generator, remote control

Tagline beams.

bollard suspension for round slings.

COG adjustment hydraulically or manual driven.

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02. 3Rotor

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02.3 ROTOR

Rotor Tilting Traverse (RTT)

Rotor Tilting Traverse (RTT)„The performance of 2 cranes“. With the AXZION Rotor Tilting Traverse (RTT) the rotor can be easily rotated in the air by 90°, either separately or even with pre-mounted rotor blades.

The integrated hydraulic cylinder tilts the beam, which in turn transfers the tilting motion across the two end slings to the rotor.

The two attachment point can be mounted in port and easily detached when the rotorstar is installed.

It‘s as simple as that. High loads are not a pro-blem, with the nearly 150.000kg rotor taking only an incredible 10 minutes to rotate.

Complete power supply redundantly driven by diesel generators.

Options: Parking feet, sea-lashing, diesel generator, remote control.

redundant energy supply.

for turning the rotor no additional crane necessary.

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02.3 ROTOR

Rotor Lifting Device

Rotor Lifting DeviceLoad carrying equipment suitable for lifting and turning a rotor. The rotor lifting device (RLD) is firmly conacted with four bolts to the attachment plates. to the rotor, the swivel-mounted eyelet then allows you to turn the rotor by 90°, either separately or with pre-mounted blades.

The main crane carries the rotor, the auxiliary crane lifts at the lower rotor blade then lets it out.

Including easy COG adjusment.

Options: Tagline points to align under load, extra-wide blade sling for the auxiliary crane

Locking bolts.

COG adjustment.

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02.3 ROTOR

Single Blade Assembly Beam

Single Blade Assembly BeamIn the middle of the forest, at a small moun-taintop assembly area, at extreme construction heights, with limited crane capacity; the rotor can‘t always be mounted on the ground and then lifted in one piece.

Instead, you have to assemble the rotor blades in-dividually, and that‘s where AXZION‘s redesigned single blade assembly beam comes into its own. The AXZION beam has a modular design and can be adjusted to the length required by the blade manufacturer.

On the crane side the beam has adjustable chains, easily allowing for different COGs. The ro-tor blade lies securely in its half-shells, equipped with Secutex protective covering.

The rotor blade is secured either by a swivel locking bolt or a clamping cylinder.

Options: Changeable blade supports Tilting mechanism Demounting of blades Diesel generator Hydraulic system

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02.3 ROTOR

500kg or 350.000kg capacity; lifting strap or round sling. Especially in wind energy, textile slings are the standard when it comes to gently lifting precious loads.

Introducing the super compact MagumX round sling made from high-strength fibres for heavy engine rooms and towers.

SpanSet lifting slings with secutex protective covering to lift the delicate rotor blades, TagLine slings to guide the rotors.

SpanSet is the market leader in high quality tex-tile lifting equipment, with an inhouse production line so it can offer customised solutions.

Slings

Slings

SpanSet Magnum X with a very compact design.

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02. 4Special Tools

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02.4 SPECIAL TOOLS

For the safe and efficient transport of high-quality components, AXZION designs and manufactures customised frames, dunnage and pallets. From to-wer segments to engine rooms and rotor blades.

With its collective knowledge in the fields of steel construction, handling, load securing (Span-Set) and material protection (Secutex), AXZION can offer customised solutions at very attractive prices.

The steel components are welded by the latest automated machines, SpanSet lashing systems and Secutex polyurethane moulded parts are integral parts of the AXZION transport equipment range.

Rain, wind and extreme weather. Fully assembled towers or even standing tower sections must be securely covered especially offshore, to protect the installation.

A simple tarp is often not the right solution. These modular „China hats“ are made of steel or aluminium and offer long-lasting weather protection.

Integrated access doors allow you to work with the Complete Tower Gripper (CTG) or even assem-ble Axzion Vario TAP.

Options: Daylight windows, Secutex flange seal IP 45, stacking device, trans port pallets for trucks or container transport.

Complete lifting equipment for the assembly and disassembly of older wind turbines. There is often a lack of lifting equipment for older wind turbines or the old material does not have the required safety credentials.

AXZION tower anchors fit every tower and come with sliding plates sizes M36 to M48. Together with the AXZION pulley set, even older systems can be removed easily.

Consits of: Axzion TAPs Axzion Pulleys Axzion Vario J-Hook

Transport Equipment „China Hat“ Tower Covers Repowering SetSpecial Tools

Need something urgently and don‘t always want to invest in the necessary lifting equipment?

From the upending tool with a capacity of 1500t up to the tower anchor point with a capacity of 17t.

For just a week or several months, the newly founded AXZION Rental GmbH rents out proven and continually tested lifting equipment, including for the installation of wind turbines.

Axzion Rental

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02. 5Services

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Maintenance, repairs and operation

According to the German Accident Prevention Regulations, lifting equipment must be tested at fixed intervals to check that it is in safe working order.

Our service team includes highly qualified experts in cranes and welding, specialists in hydraulics and electrical engineers.

These employees have the appropriate level of qualifications and are responsible for ensuring that legal provisions are complied with.

02.5 SERVICE

Maintenance, repairs and operation

Tests pursuant to the German Accident Prevention Regulations

We perform regular on-site maintenance work. This work is conducted by service staff with mul-tiple qualifications and faults are quickly detected and immediately resolved.

If a necessary component is not in stock, our efficient manufacturing plant is able to produce a replacement at short notice.

Repairs and maintenance

Minimising downtimes during operation is one of the important tasks carried out by the project management team. As part of your service agreement, our highly qualified service team is available around the clock, including at the weekend and on bank holidays.

Our employees have been trained to work offshore and can also be flown by helicopter to remote locations. By arrangement, replacement parts can be stored at our service centre in Groß-efehn, Germany, and in the future, it will also be possible for them to be stored in Denmark.

Our lifting specialists pass on their knowledge to ensure the smooth running of your lifting equip-ment and lifting operations.

Some lifting processes are extremely difficult and present additional risk. In these cases, our lifting specialists can operate the lifting equipment for you.

24/7 service

Training and operation

Point 1 of Annex I of the 2006/42/EC Machinery Directive states: “The manufacturer of machinery or his authorised representative must ensure that a risk assessment is carried out in order to deter-mine the health and safety requirements which apply to the machinery. The machinery must then be designed and constructed taking into account the results of the risk assessment.”This applies to the manufacturers of machinery that fall under the scope of this Directive. Lifting equipment is included in this.Manufacturers must perform a risk assessment that determines all risks that may arise when using the lifting equipment for its intended pur-pose and that takes into account any foreseeable misuse.To avoid possible risks and lessen the risk of dangerous situations arising, manufacturers must define measures that can be used to avoid or minimise risks.The lifting equipment must then be designed and constructed taking into account the results of the risk assessment and the measures defined.Operators of lifting equipment are obliged to carry out a risk assessment for this equipment.

The following points must be taken into account when performing this assessment:

- Interactions with other work equipment when the lifting device is in operation.- Risks that may arise when using the lifting equipment itself.- Risks that may arise between the lifting equipment and the working environment.

Moreover, when testing work equipment, opera-tors must above all determine the type and scope of the required tests, as well as when they must be carried out.

Employers also have to identify and lay down the requirements to be fulfilled by personnel appointed by them to test and trial the work equipment.

The mandatory process of analysing the risks involved in using the lifting equipment is sometimes very challenging and time-consuming.

AXZION-GKS employs highly qualified experts in lifting technology to create these analyses and carries out this work in collaboration with the equipment operators.

Risk analysis and assessment

Handling instructions that explain how to use the lifting equipment correctly are increasingly required. In addition to describing the lifting process in detail, these documents should discuss special cases.

The mandatory process of analysing the risks involved in using the lifting equipment is some-times very challenging and time-consuming.

AXZION-GKS employs highly qualified experts in lifting technology as well as specialised graphic designers to create these documents and perform these analyses, carrying out this work in collabo-ration with the equipment operators.

Handling instructions

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AXZION GKSStahl- und Maschinenbau GmbHWinkelsweg 172 40764 LangenfeldGermanyTel +49 2173 20892 0

AXZION GKSStahl- und Maschinenbau GmbHNiederlassung Nord/Ost Am Bahndamm 917235 NeustrelitzGermanyTel +49 3981 2865 0

AXZION GKSStahl- und Maschinenbau GmbHNiederlassung Nord/WestSchmiedestr. 1026629 GroßefehnGermanyTel +49 2451 484573 192

AXZION GKSStahl- und Maschinenbau GmbHNiederlassung DänemarkTel +45 60 21 45 50

info@axzion.de www.axzion.de