Assembling wind turbines: three things to consider before starting the job

Every job requires the right set of tools. So, when the job is assembling something as large as wind turbines, those tools need to be pretty big. 

Wind energy industry plays a pivotal role in the global shift towards renewable energy. However, transporting and assembling wind turbine components presents a unique set of challenges, not only because of their considerable size and weight, but because they are delicate. So, whether you’re looking at the manufacturing, transportation, or assembly stage of the broader process, you’ll find that both power and precision are required of the machines involved. 

Kalmar addresses these challenges by offering specialised heavy lifting machinery. And, because no two worksites operate the same way, we also offer tailored solutions to meet your own particular requirements. 

This guide explores three key topics that you should consider when planning your wind turbine or wind farm construction job, and how Kalmar’s solutions for wind turbine construction and assembly can support you in each of those areas. 

Consideration #1: Which machine is best suited for which turbine part? 

Wind turbines are impressive pieces of engineering, but their construction involves some of the largest and heaviest components around. Consider these typical elements: 

• Blades: Often over 80 meters long for modern turbines. 

• Nacelles: The housing for critical turbine components, weighing up to 120 tonnes. 

• Tower sections: Cylindrical parts that can exceed 30 meters in length. 

• Foundations: Massive structures designed to anchor the turbine in place. 

Handling these parts requires not just strength, but precision to avoid damage during transport and assembly. Each step in the process must balance operational efficiency with strict safety and environmental standards.  

Kalmar's range of heavy-duty machinery is engineered to safely handle large and heavy loads. Depending on the specific components you are handling, you may decide to go with reachstackers, forklifts, or a combination of the two. 

• Heavy Duty Reachstackers: Kalmar has partnered with CES for a new range of reachstackers capable of lifting up to 380 tonnes. With improved outreach and lift height, they’re ideal for large components like wind turbine blades.  
• High Capacity Industrial Reachstackers: Loads of up to 130 tonnes can be handled by Super Gloria Reachstackers — or 260 tonnes when two work in tandem. For even heavier loads, Kalmar has partnered with CES to develop the heavy-duty range of reachstackers that can handle up to 380 tonnes. These options are ideal for large components like wind turbine blades.

• Heavy Duty Forklift Trucks: Offering lifting capacities up to 85 tonnes, these forklifts can help ensure efficient and safe handling of large components like nacelles and tower sections. 

Choosing the right machine is a crucial first step, but getting it ready for the job at hand may require a specific set of attachments – that takes us to the second key consideration. 

Consideration #2: What customisations does your operation need? 

Lifting different wind turbine parts requires not only the right machine, but also the right attachments. Kalmar’s extensive range of lifting attachments, designed for blades, towers, and other turbine parts, ensures you’ll always have the right tool for the job. Whether you’re working with our electric or diesel-powered forklifts or high-capacity reachstackers, each attachment is engineered to seamlessly integrate and maximise efficiency.  

While the current range of Kalmar lifting attachments covers a lot of use cases, it’s entirely possible that your operation would benefit from something custom made. If that’s the case, no problem. Talk to your local Kalmar representative and ask about getting a lifting attachment designed and tailored to your needs. 

Consideration #3: Can you do it with electric machines? 

If your worksite has the infrastructure to support electric machines, Kalmar’s electric reachstackers and forklifts could be an ideal way to handle certain wind turbine parts while reducing fuel costs and on-site emissions. 

The Kalmar ECG180-330 Heavy Electric Forklift Truck can handle 18-33 tonne loads, while Kalmar Electric Reachstackers are designed for up to 54-tonne loads when equipped with a Tool Carrier, and up to 70-tonne loads when equipped with a Lifting Hook. Because these machines are made with a modular approach to their batteries, Kalmar can work with you to find the best charging solution for your use case. And with zero on-site emissions, they allow wind projects to reduce their environmental footprint throughout transportation and assembly. 

Let’s find the optimal solution for your wind project 

Wind plays a key role in the global transition toward renewable energy, but the assembly of wind turbines comes with its own set of challenges. That’s why Kalmar is proud to be a trusted partner in wind energy projects worldwide. With extensive experience, a global presence, and a commitment to customer-focused solutions, Kalmar is a reliable choice for handling and transporting wind turbine components.  

Reach out to your local Kalmar representative and find out how Kalmar’s solutions can help ensure efficiency, safety, and sustainability for your wind project.