Building in quality before the first weld
How PROram uses the Leica Absolute Tracker AT500 to improve accuracy and efficiency in wind-tower manufacturing
In wind-tower manufacturing, dimensional accuracy is critical long before the first section is assembled. Large steel shells must align precisely over many metres, yet the realities of rolling, welding, and handling mean that no tower section is ever a perfect cylinder. Ovality, taper, and local distortion are unavoidable, and when welded features are positioned purely from nominal CAD data, these deviations often accumulate into costly rework during final assembly.
This was the challenge faced by PROram, a Norwegian-Polish engineering company specialising in metrologydriven production support, when supporting windtower manufacturer E-Towers. To address it, PROram implemented a workflow based on the Leica Absolute Tracker AT500 that allows layout, tracing, and verification to be referenced to the actual geometry of each tower section rather than an idealised model.
PROram’s approach begins by establishing reliable datums directly on the physical part. Using the AT500, the team measures the shell geometry to compute the true main axis of the tower section, followed by precise measurement of the flange planes. These elements form the real-world reference frame for all subsequent operations.
Once this reference is defined, the nominal CAD model is transformed into the measured coordinate system. Layout points for brackets, platforms, guides, and other welded features are then traced directly onto the steel using the AT500 with the Leica B-Probeplus. Final deviations are checked immediately before the parts are released for tack-welding.
By aligning layout and welding operations to the actual axis and flange orientation, rather than to nominal geometry, PROram ensures that features are positioned correctly from the outset. This “build quality in” philosophy significantly reduces the risk of downstream corrections and misalignment when sections are joined.
In a representative wind-tower project, PROram traced approximately 90 to 100 layout points while simultaneously measuring the full section geometry. Typical tolerances for these applications fall within the single-millimetre range, with angular controls of ±0.014° (approximately ±0.5 mm) and axial tolerances of ±0.5 mm.
The resulting inspection reports showed a consistent pass pattern across all critical features. From initial measurement through tracing, tack-welding, and reporting, the complete end-to-end cycle was completed in roughly four hours. This level of efficiency allows quality control to be embedded directly into production, rather than treated as a downstream inspection step.
These time savings, combined with a significant reduction in rework and corrective welding, translate directly into financial benefits. On a per-section basis, the avoidance of rework and schedule risk saves thousands of euros, with substantial cumulative impact across multi-section towers and large-scale production runs.
This was the challenge faced by PROram, a Norwegian-Polish engineering company specialising in metrologydriven production support, when supporting windtower manufacturer E-Towers. To address it, PROram implemented a workflow based on the Leica Absolute Tracker AT500 that allows layout, tracing, and verification to be referenced to the actual geometry of each tower section rather than an idealised model.
Referencing the real geometry, not the drawing
PROram’s approach begins by establishing reliable datums directly on the physical part. Using the AT500, the team measures the shell geometry to compute the true main axis of the tower section, followed by precise measurement of the flange planes. These elements form the real-world reference frame for all subsequent operations.Once this reference is defined, the nominal CAD model is transformed into the measured coordinate system. Layout points for brackets, platforms, guides, and other welded features are then traced directly onto the steel using the AT500 with the Leica B-Probeplus. Final deviations are checked immediately before the parts are released for tack-welding.
By aligning layout and welding operations to the actual axis and flange orientation, rather than to nominal geometry, PROram ensures that features are positioned correctly from the outset. This “build quality in” philosophy significantly reduces the risk of downstream corrections and misalignment when sections are joined.
Proven performance on the shop floor
In a representative wind-tower project, PROram traced approximately 90 to 100 layout points while simultaneously measuring the full section geometry. Typical tolerances for these applications fall within the single-millimetre range, with angular controls of ±0.014° (approximately ±0.5 mm) and axial tolerances of ±0.5 mm.The resulting inspection reports showed a consistent pass pattern across all critical features. From initial measurement through tracing, tack-welding, and reporting, the complete end-to-end cycle was completed in roughly four hours. This level of efficiency allows quality control to be embedded directly into production, rather than treated as a downstream inspection step.
Measurable gains in productivity and cost
Since adopting the AT500-based workflow, PROram has achieved approximately 40% higher measurement throughput on wind-tower projects. Early trace-marking referenced to the actual axis and flanges has shortened critical production steps by up to 30%.These time savings, combined with a significant reduction in rework and corrective welding, translate directly into financial benefits. On a per-section basis, the avoidance of rework and schedule risk saves thousands of euros, with substantial cumulative impact across multi-section towers and large-scale production runs.
“With the AT500 we reference the actual tower axis and flanges, trace points on steel, and let welders tack in the right place the first time.”
Rafał Milczarski
CEO, PROram
Why the Leica Absolute Tracker AT500
PROram selected the Leica Absolute Tracker AT500 to support production-adjacent tasks in demanding industrial environments. Battery operation, wireless connectivity, fast setup, Hexagon’s patented PowerLock technology, and compatibility with the Leica B-Probeplus make the system particularly well suited for work inside large steel structures.Beyond accuracy and repeatability, the portability of the AT500 enables faster execution without compromising measurement quality. Seamless integration with Hexagon’s scanning ecosystem further supports flexible workflows across inspection, layout, and verification tasks. Today, the AT500 is used daily by PROram across wind energy, offshore, and heavy-industry applications.
Partnership and local support
From its foundation, PROram has relied on solutions from Hexagon. Equally important has been the support of Hexagon’s local partner, Precinor. Fast demonstrations, hands-on training, responsive service, and application support have allowed PROram to deploy new technology quickly and with confidence.According to Rafał Milczarski, CEO of PROram, this partnership approach is essential for onsite industrial work. “We secure quality before the first weld. With the AT500 we reference the actual tower axis and flanges, trace points on steel, and let welders tack in the right place the first time,” he explains.
About PROram
PROram was founded in 2020 and operates from Norway and Poland with a team of more than 20 specialists. Its core pillar, ProScan, delivers 3D metrology and engineering services powered by Hexagon technologies.
With a constructive, production-oriented mindset, PROram supports customers across wind energy, offshore, heavy industry, construction, and machinery manufacturing. Digitalisation is treated not as an end in itself, but as a practical tool to improve operations, quality, and efficiency on the shop floor.
Hexagon’s reflectors are premium targets for precise measurement results and – together with PowerLock – allow users to instantly re-establish an interrupted beam from the laser tracker.
For PROram, the Leica Absolute Tracker AT500 is a portable system that reliably supports both inspection and production‑adjacent tasks, such as early trace‑marking, while also providing smooth software integration.
