Wind farm project utilises SCHEUERLE BladeLifter systems

With rotor blade lengths approaching 90 metres, transports for modern wind turbines have evolved into highly complex operations.

The wind farm project in Bad Berleburg clearly demonstrates the level of challenge involved: A total of 60 rotor blades of the E-175 EP5 E1 type, each measuring 85.85 metres, are being transported safely to site in several stages using three SCHEUERLE BladeLifter systems, mounted on 16 axle lines of modular platform trailers.

The route is divided into three sections with a total length of around 45 kilometres. In the first two sections of 25 and 12 kilometres, the SCHEUERLE BladeLifters – mounted on fully modular platform trailers – are operated in towed configuration. On the final 8-kilometre section, the same combinations switch to self-propelled mode. The transport combinations reach lengths of up to 103 metres in towed operation and 96 metres in self-propelled configuration. The blade pitch angle varies between 21 and 46 degrees depending on route requirements, with the SCHEUERLE BladeLifter technically capable of up to 60 degrees.

The transport routes around Bad Berleburg place the highest demands on both personnel and equipment. Tight serpentines, underpasses, challenging village sections and an aqueduct along a former railway line require maximum precision. At the same time, numerous protected trees along the route must be preserved, adding further constraints to route planning.

“The challenge lies primarily in the combination of demanding route conditions and constantly changing environments. Tight curves, varying elevations and weather influences such as wind and fog require full control of the rotor blade at all times. In situations like these, experience and well-coordinated team processes make all the difference,” explains Björn Feddermann, Global Logistics Project Manager for Self-Propelled Modular Transporters within the Enercon SPMT & Cranes team.

This is where a key advantage of the SCHEUERLE BladeLifter becomes apparent: by actively lifting the rotor blade, obstacles such as trees can be safely cleared. The blade is raised and manoeuvred in a controlled manner over obstacles, eliminating the need for intervention in existing infrastructure or vegetation. Even in sensitive areas, tree felling can therefore be avoided and environmental impact kept to a minimum.

In addition, varying environmental conditions at different elevations as well as demanding gradients within the wind farm of up to 12 to 16 per cent present further challenges. Wind, fog and, at the beginning of the project, winter conditions including snow and ice all add to the complexity. Transports are carried out both during the day and at night in order to make optimal use of the available conditions.

A total of three SCHEUERLE BladeLifters – mounted on 16 axle lines of SCHEUERLE modular platform trailers – are in operation. Two systems are operated by the heavy haulage specialist Steil Kranarbeiten, with a third operated by ENERCON.The simultaneous coordination of the three teams, along with the alignment of additional transports for tower sections and other components, requires precise planning and close cooperation between all parties involved.

“These types of transports only work as a team effort. With three BladeLifters operating in parallel and varying requirements along the route, coordination between the teams was crucial. In particular, the collaboration between the ENERCON ‘BladeHornet’ team and the Steil teams demonstrated how important well-rehearsed processes are,” says Manuel Eck, Project Manager at Steil Kranarbeiten.

In addition to the operational execution, all regulatory requirements must be fulfilled, including the use of BF4 escort vehicles for traffic management as well as police support.

As the output of modern wind turbines continues to increase, so too do the demands placed on transport solutions. Projects such as the one in Bad Berleburg demonstrate that innovative technology and experienced teams must work hand in hand to make such developments possible.

Regardless of how future energy systems are structured, without capable heavy transport logistics, they remain theoretical.