New Blade Adapter Trailer Eases Transport of 80-Meter-Long Wind Turbine Blades

Collett & Sons Ltd., a global transport logistics company, has successfully completed the delivery of 90 wind turbine components to the Cushaling Wind Farm in Ireland.

“This milestone project is a significant addition to our renewables portfolio, and we are proud to have contributed to Ireland’s renewable energy goals,” the company said. The delivered components included nine nacelles, hubs, and power trains; 36 tower sections; and 27 blades, which had been stored at and were loaded from Port of Waterford, Ireland (Figure 1).

The project included record-breaking 80-meter-long blades, the longest onshore turbine blades ever delivered in Ireland and the UK (Figure 2). Once operational, Cushaling Wind Farm will feature nine V162 Vestas Enventus turbines, the first of their kind used in both countries.

Collett utilized its latest renewable energy fleet addition, the “Blade Adapter trailer” (also known as the clamp and dolly system), to transport the blades (Figure 3). The innovative design, developed by trailer manufacturer DOLL, was used for the first time in both Ireland and the UK. It provides improved ground clearance, enhanced maneuverability, and greater stability compared to standard Super Wing Carrier trailers.

The Blade Adaptor requires 2 meters less space for turning at bends than a 65-meter platform trailer (Figures 4 and 5), ensuring safer driving with high centers of gravity. Despite the impressive total vehicle length of 93 meters, the Blade Adapter is designed to be universally compatible with blades of up to 120 meters.

The power trains and hubs were transported on 8-axle and 6-axle steerable trailers, respectively, while the nacelle components were delivered using Collett’s 3-7 Nooteboom clamps. All tower sections (bottom, mid 1, mid 2, and top) were also transported using 3-7 Nooteboom clamps.

All components, except the blades, were transported directly from port to site, following a 295-kilometer route. Undertaking nighttime deliveries (Figure 6) in order to minimize road traffic disruption, the route took approximately 10 hours including a rest break along the M4. Due to the blades’ length, distance, and complexity of the route, a different route was utilized and spread over two nights.

En route to the wind farm, Collett’s drivers had to perform several complex maneuvers. A 3-point turn was required at R402 just before Georges Bridge. The junction required several amendments, which included tree trimming and a purpose-built turning head created off the R402 to enable the vehicles to drive onto the R401. A second 3-point turn was performed further down the R401 to facilitate entry into the site.

Preliminary works included a test run from port to site, using a Super Wing Carrier trailer with 11-meter rear projection to simulate the actual blade transportation and 93-meter total vehicle length. This identified the need for road widening, removal of street furniture, and tree trimmings along the route. Temporary infrastructure adjustments, road closures, and contraflow systems were implemented to accommodate the blades’ dimensions. These measures were especially necessary in the Ballinagar and Daingean villages, where blades had to carefully over-sail steel bollards and traffic islands were removed to ensure safe passage. Traffic management and police escort arrangements were made throughout to ensure a safe delivery.

Upon arrival at the site, each component was delivered to its respective pad. Whilst on site, Collett’s team skillfully navigated multiple pinch points several times, including a bridge located between pads 3 and 4, in the process of delivering the necessary components.

“Our success in this project was made possible through effective collaboration, strategic planning within our team, advanced logistics, and community liaison with councils and the police, ensuring a smooth execution,” the company said.

“Cushaling was an extremely challenging and technically difficult project, especially managing this size of blades in nighttime delivery conditions. However, we’ve come through the other side and delivered the project successfully, which is a tremendous achievement. Our Blade Adapter trailers have been a game-changer in allowing us to transport the longest onshore blades to date on land across Ireland and the UK,” said Jack Collett, renewables director at Collett & Sons Ltd.

“We’re so proud of our team, who are a makeup of individuals that work extremely hard and dedicated to providing a quality service for our customers. I’d also like to extend our gratitude to our partners at ELS for their assistance with permits and pilots for each movement, and for their management of the Garda escorts, as well as to Celtic Shipping and the Port of Waterford for their assistance with handling the cargo over the quay,” he added.

—POWER edited this content, which was contributed by Collett & Sons Ltd.’s Marketing department.