WIND ENERGY METROLOGY

Wind Farm

Behind the Measurements

ALTO provides energy-sector dimensional inspection, metrology services and integrated solutions worldwide, with a strong operational focus on the UAE, Saudi Arabia, Qatar, Bahrain, the wider Middle East and Africa. Our engineers support renewable, conventional and critical-energy projects throughout fabrication, assembly, installation, maintenance and quality-control activities.

We combine specialist metrology expertise with advanced technologies from Hexagon and Creaform. Our capabilities include laser tracker measurement, 3D scanning, photogrammetry, portable measuring-arm inspection, reverse engineering, virtual assembly and remote data analysis. ALTO also develops measurement and reporting workflows using SpatialAnalyzer and PolyWorks.

Wind Energy Dimensional Inspection

ALTO supports the energy transition by providing dimensional inspection and engineering services for onshore and offshore wind projects. Accurate measurement and virtual assembly help manufacturers and contractors verify critical interfaces, reduce fit-up risks and prevent costly modifications during final installation.

Monopile and transition-piece inspection: Dimensional verification of primary structures, flanges, interfaces and critical assembly features.
Flange inspection: Measurement of flatness, diameter, bolt-hole position, concentricity, orientation and interface geometry.
Virtual assembly and matching: Analysis of separately manufactured components to predict fit-up, determine the optimal assembly orientation and identify potential clashes before mobilisation.
Secondary-steel inspection: Dimensional control of boat landings, J-tubes, platforms, ladders and other secondary structures.
Fabrication monitoring: Measurement during manufacturing to identify deformation and dimensional deviations before completion.
Remote data analysis: Processing and evaluation of measurement data collected at different fabrication facilities or project locations.
Professional reporting: Clear dimensional reports, deviation maps and virtual-assembly results for engineering review and project documentation.

Metrology for Power Generation

Beyond wind energy, ALTO provides dimensional inspection, alignment and reverse-engineering support for gas, steam, hydroelectric and nuclear power-generation projects.

Turbine and generator alignment: Laser tracker measurement of shafts, bearings, couplings, casings, diaphragms and machine centre lines.
Installation and maintenance support: Real-time dimensional data to guide mechanical adjustments during installation, overhaul and maintenance activities.
Component inspection: Verification of turbines, generators, casings, rotors and critical interfaces against drawings or CAD models.
3D scanning and reverse engineering: Digital capture and CAD reconstruction of worn, modified, obsolete or undocumented components.
SpatialAnalyzer and PolyWorks programming: Development of measurement plans, alignment routines, analysis workflows and customised inspection reports.

Integrated Metrology Solutions for the Energy Sector

ALTO supports customers from measurement planning and feasibility assessment through on-site execution, data analysis and final reporting. We can provide an individual inspection service, long-term project support or a complete solution incorporating measurement hardware, software, automation and operator guidance.

Our approach helps energy companies, fabricators and installation contractors improve dimensional control, reduce assembly risks and make informed decisions before components reach their final installation site.

Partner with ALTO for energy-sector metrology support worldwide and rapid mobilisation across the UAE, Saudi Arabia, Qatar, Bahrain, the wider Middle East, Africa and China

MP & TP inspection and Matching Exercise Moray WEST

Off-Shore Rover

Unmanned offshore rover for wind farm foundation measurements. Autonomous flange flatness, tilt, and ovality analysis with instant reporting.

Laser tracker survey measuring the flatness and ovality of a wind farm transition piece flange.

Transition Pieces

ALTO provides laser tracker inspection of offshore wind transition pieces across the Middle East, Africa and worldwide. Measurements include flange flatness, ovality, tilt, BCD, bolt-hole diameter and interface geometry, supported by detailed 3D reporting.

Measuring offshore wind farm jacket components using a Leica Absolute Tracker AT960 in a heavy fabrication yard.

MonoPile and Jackets

ALTO provides monopile jacket inspection with Leica and FARO laser trackers for offshore wind projects worldwide. Our dimensional inspection services cover ovality, straightness, flange flatness, BCD, interface geometry and virtual fit-up analysis.

Virtual Assembly

3D digital measurement and virtual assembly simulation. Detect gaps and collisions before fabrication to optimize production.

Topside metrology using a total station for deck flatness and column positioning on an offshore platform.

Offshore Topside Inspection

Offshore topside inspection using total stations and laser scanning for deck flatness, column positioning, structural alignment and virtual assembly.

Offshore Rover

PROMETEO is an autonomous robotic system developed by ALTO and AXIST for high-precision monopile flange inspection offshore. Deployed directly onto the flange by crane, it performs a complete non-contact 3D inspection in approximately 30–40 minutes without placing personnel on the structure.

The system measures flange flatness, local run-out, tilt, ovality and monopile inclination while also recording visual evidence of surface conditions. Designed for demanding marine environments, PROMETEO reduces offshore inspection time, vessel costs and HSE risks while delivering reliable, traceable measurement data for offshore wind installation.

Offshore photogrammetry and laser tracking for non-invasive flange inspection of transition pieces.

Offshore Flange Inspection

ALTO provides offshore flange inspection of monopiles and transition pieces using high-accuracy laser trackers and photogrammetry systems. Measurements verify flange flatness, bolt-circle diameter, hole and stud positions, ovality, tilt and local geometric deviations.

Measured monopile and transition-piece data can be digitally matched before offshore installation. ALTO evaluates different rotational positions to identify the most suitable MP–TP pairing, detect potential hole and stud clashes, verify guiding-pin compatibility and predict interface gaps or required shimming.

Clear digital reports allow manufacturers, installation contractors and project teams to assess flange geometry and compatibility before load-out and offshore assembly. ALTO performs offshore wind flange inspection and remote data analysis worldwide, including the UAE, Saudi Arabia and Africa.
we have delivered successful projects with RWE ocean wind Inch cape Damen Jan de Null

TP -Transition Piece Flange Inspection

Transition piece flange inspection is essential for confirming the dimensional condition and installation readiness of offshore wind foundations. ALTO uses high-accuracy laser trackers and industrial photogrammetry to perform rapid, traceable measurements during manufacturing, assembly and offshore installation.

Our inspection covers flange flatness, ovality, bolt-circle diameter (BCD), bolt-hole diameter (BHD), bolt-hole orientation, flange tilt and interface geometry. Measurement results are analysed in SpatialAnalyzer and delivered through clear 3D inspection reports.

ALTO can also compare monopile and transition piece flange data to perform virtual matching, identify bolt-hole clashes, calculate angular rotation and predict interface gaps before installation. This reduces offshore modifications, installation delays and project risk.

Services are available across the UAE, Saudi Arabia, Bahrain, Qatar, Africa, Europe and international offshore wind locations.

Technician using SuPAR augmented reality software to perform a real-time CAD-to-part visual inspection.

SuPAR AR Visual Inspection

SuPAR AR visual inspection connects digital CAD data with physical components using augmented reality. The application overlays design geometry directly onto the real part, helping operators identify discrepancies, verify component positioning and follow assembly instructions.

Users can capture photographs, add comments and document quality issues directly during inspection. The collected information can be shared through PDF, Excel and 3D reports, improving traceability and communication between production, quality and engineering teams.

SuPAR supports visual quality control, assembly guidance, maintenance and collaborative inspection activities. ALTO provides application assessment, configuration, implementation and training across the UAE, Saudi Arabia and Africa.

On-site machine alignment using a portable laser tracker to measure and align large, non-dismantlable industrial machinery components.

On-Site Milling Machine Alignment

ALTO provides on-site alignment of portable milling machines using high-accuracy laser trackers across the UAE, Saudi Arabia and the Middle East. We establish machining references, guide equipment positioning and perform pre- and post-machining dimensional inspection on large components that cannot be moved to a conventional CNC machine.

Do you want to know more or need a consultation?

Metrology links the virtual and the real world together. At ALTO we know how to accomplish this in the most efficient way