G+ represents major offshore wind operators and works to improve safety, efficiency, and collaboration across the sector. Supported by Innovate UK’s Innovation Exchange (iX) programme, G+ launched a challenge to identify innovative solutions that could reduce the physical strain placed on technicians during turbine installation.

As the offshore wind industry continues to scale and bring down costs, the organisation recognised the need to look beyond its traditional supply chain and connect with innovators from other industries, bringing in technologies and approaches that have been proven elsewhere but not yet applied in offshore wind.

Reducing manual handling at height

G+ identified a significant issue in the manual installation of turbine bolts. These bolts can weigh up to 20 kilograms, and hundreds may be required per turbine. Technicians are often required to work above head height for prolonged periods, placing strain on their backs, muscles, and joints.

The challenge focused on finding practical solutions that could reduce fatigue and injury risk while maintaining efficiency in demanding offshore conditions.

Exploring practical, scalable solutions

Through the iX process, G+ opened the problem to a wide range of innovators across multiple sectors. Solutions explored included mechanical lifting tools, digital and sensing technologies, and biomechanical support systems.

The selected solution was a Hilti exoskeleton suit, supplied by Gibb Group. The exoskeleton suit is designed to support technicians working with their arms raised above head height. The suit is fully adjustable and allows users to change strength and tension settings to suit different body types and task requirements. It also includes neck support to reduce strain during prolonged overhead work.

Wider impact and future opportunities

Following the success of the bolt handling challenge, G+ has launched a further challenge focused on grease removal from large turbine components, which has already attracted strong engagement and is due to be announced soon.
G+ plans to continue working with iX and a wide network of partners, including turbine manufacturers, investors, and utility companies, to address challenges across the offshore wind delivery chain and identify approaches that can improve safety and efficiency across the wider industry.

A collaborative experience

Reflecting on the process, G+ highlighted the value of iX in connecting offshore wind operators with innovators from outside the sector. The iX team helped translate technical requirements clearly and supported communication between challenge holders and solution providers.

What the Innovation Exchange programme gave us was a connection with the outside world, bringing in other industries and other technologies and applying that to offshore wind.

– Kate Harvey FEI, G+ Global Offshore Wind Health and Safety Organisation General Manager