Wind Energy Lifting Challenges & Solutions
- Challenges in Wind Turbine Lifting
- Modulift’s Solutions for Wind Turbine Lifting
- Case Studies
- Conclusion
Wind energy has become a cornerstone of the global transition to renewable power. As wind turbines increase in size and scale—both onshore and offshore—the lifting challenges associated with their installation and maintenance have grown more complex. From long, delicate blades to heavy nacelles and towering structures, each component presents unique rigging and handling requirements. This article explores these challenges and the innovative solutions provided by lifting and spreader equipment, with a focus on how Modulift’s modular systems address them.
Challenges in Wind Turbine Lifting
1. Blade Lifting
Wind turbine blades are long and lightweight—making them vulnerable to wind gusts during lifting. Their curved shape and composite material structure require even load distribution and minimal point pressure. Improper rigging can lead to damage or dangerous instability during hoisting.
Modulift’s Lattice Spreader Beams are ideal for long, light loads where a standard Spreader Beam is deemed too short for the lift. The Lattice Spreader Beam has been designed to be lightweight so as to allow for easy transportation and storage as well as being a cost-effective piece of lifting equipment.
2. Nacelle Lifting
Nacelles house the gearbox, generator, and control systems and can weigh over 100 tonnes. Lifting them requires equipment with high load capacity, stability, and precise rigging. The center of gravity must be accurately calculated to ensure level lifting, especially in offshore environments where motion from sea conditions adds complexity.
3. Monopile Lifting
Monopiles are large cylindrical steel structures lifted and stacked at great heights. Their size and weight demand heavy-duty lifting frames or spreaders to prevent bending, imbalance, or slippage. Offshore tower installation further complicates lifting due to barge movement, crane reach limitations, and time constraints driven by weather windows.
Modulift’s Solutions for Wind Turbine Lifting
Modulift’s range of modular spreader beams, lattice beams and custom designed lifting solutions provide the flexibility and strength needed for lifting large and complex components. Beams can be configured to different spans and load requirements, making them suitable for lifting blades, nacelles, and tower sections of various sizes.
Spreader beams ensure even load distribution, reducing stress concentrations on delicate components like blades. By spreading the lifting points, the equipment minimises deformation and enhances control over large, flexible structures.
Modulift equipment has been successfully deployed in challenging offshore environments, including floating barge lifts and wind farm construction. Their corrosion-resistant finishes and ability to integrate with subsea and marine rigging ensure reliability in harsh conditions.
Case Studies
Modulift Provide a Record First Lifting Solution for the Wind Energy Industry and Harland and Wolff
Modulift designed and manufactured the giant lifting rig used for the fast and efficient lifting and assembly of the Repower’s 5MW giant wind turbines at Harland and Wolff in N. Ireland. Responsible for the unloading and assembly of the clean power generators for Vattenfall’s Ormonde Offshore Wind Farm Project in the Irish Sea, Harland and Wolff also have to load them back onto the barges when assembled, for installation in the Irish Sea, creating a need for a rig that could multi-task.
Modulift’s Expansion into Wind Energy Sector Accelerates with Wind Tower Lift in South America
In Colombia, a MOD 250 beam was used to safely lift 63t wind tower sections for a remote project site.
The rise in renewable energy sources has accelerated demand for Modulift spreader beams to lift turbines, towers and monopiles at onshore and offshore wind farms worldwide. As part of this expansion, global ship operator G2 Ocean deployed a Modulift Spreader Beam to Colombia for the lift of a 63mt Nordex Wind Tower.
ST3 Lifts Jacket Foundations for Wind Farm with Modulift Beams
Modulift supplied two large spreader beams to complete a rig that lifted 20 wind farm jacket foundations onto vessels at ST3 Offshore’s dockside location in Szczecin, Poland, close to the country’s north-western border with Germany. The jackets were bound for Cuxhaven and were installed at the Borkum Riffgrund 2 offshore wind farm.
Conclusion
Wind energy projects depend on precise, safe, and adaptable lifting solutions. The scale of turbine components demands equipment that offers both strength and flexibility. Modulift’s modular spreader & lattice beams provide an engineered response to these challenges—supporting efficient, compliant, and safe lifting operations in both onshore and offshore wind energy environments. Call 01202 621 511 or email [email protected] to find out how we can help with your next wind energy lift.