Lighter materials, smarter technology and stronger performance – KONE’s high-rise elevator systems are built for the next generation of skyscrapers.
Australia’s skyline is reaching new heights. In Sydney, Melbourne and Brisbane, towers are rising fast, reshaping cityscapes and demanding infrastructure that keeps pace. In this vertical race, elevator systems are more than just a convenience – they are essential to functionality, efficiency and sustainability.
For buildings designed to stand for decades, elevators must be built for the long haul. KONE has engineered its High-Rise MiniSpace DX system to meet this challenge, optimising space, reducing lifecycle costs and improving energy efficiency. With lightweight hoisting technology and a new precision control system, it ensures smooth operation and minimal service interruptions – an advantage for both new developments and modernisation projects.
A key innovation behind these advancements is UltraRope, a carbon-fibre hoisting solution replacing traditional steel ropes. Weighing 80 per cent less than steel, UltraRope reduces strain on elevator systems, enabling a more compact setup while maintaining speed and safety. Originally developed for mega-towers reaching 1,000 metres in height, it has also proven valuable in high-rises as low as 70 to 80 metres, where efficiency is equally critical.
“Because UltraRope is significantly lighter, we can downsize motor room machinery and optimise shaft dimensions. We have also integrated a new control system that provides much more precise lift positioning within the shaft,” says Robert Haig, head of major projects at KONE.
“Together, these advancements allow us to optimise vertical space in new construction, reducing headroom at the top of the shaft, pit depth at the bottom and the height of the machine room. The result is substantial cost savings in both construction and excavation.”
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Reducing pit depth also simplifies compliance. Under Australian and international lift codes, pits exceeding certain depths require access doors instead of ladders, adding complexity and cost. The High-Rise MiniSpace DX can eliminate this requirement, streamlining construction. Likewise, lower headroom and machine room height allow for more usable space within planning constraints.
“In some cases, this allows for an additional floor to be accommodated within the building while still complying with planning regulations,” says Haig.
Historically, taller buildings required deeper lift pits, as faster lifts demanded greater clearance. This increased construction costs, particularly where excavation was required.
For modernisation projects, where existing shaft dimensions are fixed, the system can enhance lift speed, improving passenger flow and reducing wait times.
“UltraRope, along with the improved positioning system, plays a key role in reducing critical dimensions within the lift shaft,” says Haig.
“We have worked with customers in Australia modernising their buildings to improve capacity. Our approach delivers distinct advantages: first, reducing lift downtime; second, increasing speeds to cut travel times. The result is an improved experience for building occupants.”
In one project, KONE doubled the lift speed within existing constraints. Each modernisation project is assessed individually, as shaft dimensions and designs vary, but in this case, sufficient pit depth, headroom and machine room height allowed KONE to increase speed from 5 to 10 metres per second.
“Each project is assessed case by case. Many customers come to us when their lift systems near the end of their operational life,” says Haig.
“Traditionally, modernisation focused on like-for-like replacements with some upgrades to meet code requirements, improve safety and integrate new technologies. Now, we are seeing a shift. By increasing lift capacity and reducing energy consumption, we can enhance building efficiency.”
For example, instead of a floor being occupied at a density of one person per 12 square metres, KONE’s solutions may enable occupancy at one per 10 square metres, allowing building owners to lease office spaces at a higher density and maximise commercial potential.
“You do not have to follow the same traditional approach,” says Haig. “With new technology, we can help rethink strategy and achieve greater efficiency with existing assets.”
Sustainability is another driving force behind KONE’s high-rise solutions. A lift’s energy consumption largely depends on the weight of its moving components – the counterweight, lift car and ropes.
“Since UltraRope is 80 per cent lighter than steel ropes, the total weight being moved is reduced,” says Haig. “This translates to lower energy consumption per journey.”
Steel ropes typically need replacing every four to five years, generating material waste. UltraRope, certified to last 15 years without replacement, minimises waste and reduces environmental impact. For new builds, the High-Rise MiniSpace DX’s lower energy consumption, smaller motors and extended lifespan contribute to better Green Star and NABERS ratings by improving efficiency and reducing material use.
“Many of the same benefits apply to modernisation projects,” says Haig. “In one case, our high-rise technology contributed to a half-star improvement in an existing building’s NABERS rating, highlighting its impact on sustainability.”
Maintenance is another area where UltraRope offers an advantage. Replacing steel ropes is labour-intensive and disrupts lift availability.
“In a high-rise office tower with 18 lifts, each would be out of service for about two days every four to five years for re-roping. While that may not seem significant for one lift, the cumulative downtime is substantial,” says Haig.
“By eliminating frequent replacements, UltraRope ensures higher uptime throughout a building’s lifecycle.”
Fewer rope replacements also mean fewer manual handling risks for technicians. Being much lighter than steel, UltraRope reduces the physical strain of installation and does not require lubrication, eliminating the use of oils and chemicals typically needed for steel ropes. This contributes to a cleaner, safer working environment.
As buildings grow taller and cities become denser, elevator systems are evolving to be faster, smarter and more efficient.
“We can now fit faster lifts into smaller footprints and, in some cases, reduce the number of lifts needed in a group, as they can travel faster within the required dimensions,” says Haig.
“This brings greater efficiency through reduced rope replacements, optimised spatial requirements and improved control systems.
“Maintenance is becoming smarter, lifts are getting more intelligent, and we are doing more with less.”
From developers and contractors to building managers and occupants, KONE’s high‑rise elevator systems are designed to move people – and buildings – into the future.