Engineering Design & Fabrication Services

What We Do

Our engineering and fabrication services cover the full lifecycle of bespoke equipment and modifications:

• Concept development and feasibility studies
• Detailed design and engineering calculations
• 3D modelling, drawings and documentation
• Prototype manufacture and functional testing
• Series production, FAT and certification
• On-site installation, commissioning and integration

We can deliver stand‑alone engineered solutions or integrate them into wider Certex packages (LOLER/PUWER inspections, crane services, NDT, wire rope and rigging).

Lifting & Handling Design

We design and engineer bespoke lifting and handling solutions to meet specific tasks, environments and standards, including:

• Lifting beams, spreader beams and lifting frames
• Yokes, strongbacks and custom lifting brackets
• Specialised hoisting and handling tools for maintenance and construction
• Dedicated lifting points, pad eyes and anchor systems
• Adaptations to existing lifting equipment to handle new loads or configurations

Our designs follow relevant standards and good practice, with a focus on safety, ergonomics, repeatability and ease of inspection.

Universal Blade Grippers & Blade Handling

Certex UK designs and manufactures universal blade grippers and handling tools to support safe, efficient wind turbine blade operations.

• Engineered for lifting, rotation and precise positioning of blades
• Suitable for installation, maintenance and repair activities
• Designed to meet OEM requirements and site-specific constraints
• Enhances safety, control and operational efficiency on site

Our solutions help streamline blade handling processes while maintaining the highest standards of safety and reliability.

Turbine Component Handling Solutions

Certex UK provides bespoke and modular handling solutions for major wind turbine components across a range of platforms.

• Handling tools for nacelles, hubs, generators, shafts and tower sections
• Modular laydown systems compatible with multiple turbine models
• Reduces need for multiple bespoke rigs and fixtures
• Enables faster changeovers and standardised procedures

These solutions deliver reduced downtime, lower project costs, and improved fleet-wide efficiency for windfarm operators and service providers.

Engineering Tools & Verification

Our engineers use modern design tools and methods to ensure robust solutions:

• 3D CAD modelling for clear visualisation and clash detection
• Engineering calculations and structural verification (e.g. stress, deflection, stability)
• Finite Element Analysis (FEA) where appropriate for more complex structures
• Lift studies, load path and interface checks

We produce full drawing packages, parts lists and calculation reports as part of the delivery.

Fabrication, Testing & Certification

Certex UK can fabricate and deliver complete turnkey solutions:

• Fabrication in approved workshops using qualified welders and procedures
• Surface treatment and coatings suitable for onshore, offshore and marine environments
• Non‑destructive testing (MPI, DPI, etc.) on critical welds and components
• Proof load testing and functional testing (on‑site or in our test facilities)
• Documentation packs including drawings, material certificates, test reports and user instructions

Where required, we align with relevant directives, standards and client specifications, and can support UKCA/CE‑related documentation for certain product types.

Integration with Certex Services

Our engineering and fabrication services are closely integrated with other Certex capabilities, including:

• LOLER, PUWER and Work at Height examinations
• Crane services – installation, modification, load testing and maintenance
• Non-Destructive Testing & Proof Loading
• Rigging and lift planning services

This integrated approach allows us to take a problem from concept through design, manufacture, testing, documentation and ongoing inspection within a single organisation.

Why Choose Certex UK for Engineering & Fabrication?

• In‑house engineering team with lifting, structural, wind and access design experience
• End‑to‑end capability – design, fabrication, testing, installation and documentation
• Wind-specialist solutions – blade grippers, turbine component handling tools and modular universal laydown systems that work across multiple turbine models and OEMs, reducing downtime and cost
• Integrated services with inspections, crane support, NDT and rigging
• Onshore and offshore experience, supporting UK and international projects
• Focus on safety, practicality and compliance, with clear documentation and traceability

To discuss an engineering challenge, bespoke lifting device, wind turbine handling tool, access solution or modification project, contact our team.