Overview
AFE Crane designed and installed a freestanding runway crane system for TPI Composites, a leading manufacturer of wind turbine blades in Newton, Iowa. As a major player in the wind energy sector, TPI required a robust material handling solution to support the heavy lifting needs associated with producing large wind turbine blades. Their existing setup was no longer sufficient to handle the increasing production demands and the sheer size and weight of the blades.
Project Challenges
The primary challenge was designing a system capable of efficiently handling massive wind turbine blades while ensuring operational safety and workflow optimization. The facility required a lifting solution that could accommodate increasing production demands without overloading the existing structure. Additionally, integrating a safe and user-friendly control system was critical to enhance efficiency and minimize workplace hazards.
The AFE Crane Solution
To address these challenges, AFE Crane developed a custom freestanding runway crane system. The system featured four 3-ton cranes with a 48-foot span, utilizing Yale Global King electric wire rope hoists. The design included 750 feet of freestanding runways, split into a 300-foot section and a 450-foot section running side by side, supported by 30-foot columns. Crane segregation controls were implemented to prevent overloading the freestanding runway, ensuring safe and efficient operation.
AFE Crane integrated Magnetek A/B/Both Radio Wireless Controls, enabling two cranes to be controlled from a single handheld transmitter. Strobe lights were added to enhance workplace safety by indicating when a crane was active. Additionally, cord reels fixed to each hoist provided 460-3-60 power, with a 30-amp plug attached to the hoist’s hook block for powering below-the-hook lifting devices. The system also incorporated several Caldwell Posi-Turner below-the-hook lifting devices, allowing for precise rotation of wind turbine blades during manufacturing.
Project Execution
All components of the crane system, including the 100,000 pounds of steel used for the structure, were fabricated at AFE Crane’s facility in Cedar Falls, Iowa. This local fabrication ensured quality control and allowed AFE to meet the project’s specific requirements efficiently. The expert installation team completed the on-site assembly, installation, and testing to guarantee the system operated safely and efficiently.
The project involved several key phases:
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Consultation and planning to understand the client’s specific needs
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Custom design and engineering to fit the facility’s layout and production workflow
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Fabrication of the steel structure and crane components
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On-site installation by AFE Crane’s skilled team
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Comprehensive testing to ensure system safety and efficiency
Conclusion
The new crane system significantly improved TPI Composites’ manufacturing efficiency, reducing the time required to move and position large components. It also enhanced workplace safety by providing a more reliable lifting solution, reducing the risk of accidents and injuries. By fabricating the steel structure and cranes locally in Cedar Falls, AFE Crane leveraged its expertise and resources to deliver a high-quality installation that exceeded the client’s expectations.
Paul Ellis, an engineer with TPI Composites, shared his experience:
“AFE Crane has provided several large crane and rigging systems for us. As a manufacturer in the wind energy industry, we are dependent upon safe and effective crane systems for our production processes. AFE has always provided great input at the system design level and the most professional and effective installation crews we have worked with. We have several crane systems as well as specially designed lifting beams and rigging systems for handling large components. With AFE’s help, we have been able to quickly and economically expand the capabilities of our cranes and rigging to accommodate ever-larger wind blade components. AFE is a great resource for any overhead handling application.”
The client expressed high satisfaction with the new crane system, noting significant improvements in production efficiency and workplace safety. The successful completion of this project reinforces AFE Crane’s reputation as a trusted partner in the wind energy sector. By leveraging local fabrication capabilities and engineering expertise, AFE Crane delivered a tailored, high-quality solution that supports the advancement of renewable energy manufacturing in Newton, Iowa.
