New Blade Adapter Transports 80m Blades to Complete Cushaling Wind Farm

This milestone project is a significant addition to Collett's renewables portfolio. The delivered components including 9 nacelles, 9 hubs, 9 power trains, 36 tower sections and 27 blades were stored and loaded from Port of Waterford, Ireland.

This included the record-breaking 80 metre long blades, the longest onshore turbine blades ever delivered in the history of Ireland and the UK. Once operational, Cushaling Wind Farm will feature nine V162 Vestas Enventus turbines, the first of their kind used in both countries.

The company utilised their latest renewable energy fleet addition, the Blade Adapter trailer (also known as the clamp and dolly system), to transport the blades. This 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 manoeuvrability and greater stability compared to standard Super Wing Carrier trailers.

The Blade Adaptor requires 2 metres less space for turning at bends than a 65 metre platform trailer, ensuring safer driving with high centres of gravity. Despite the impressive total vehicle length of 93 metre, the Blade Adapter is designed to be universally compatible with blades of up to 120 metres.

The power trains hubs were transported on 8-axle and 6-axle steerable trailers respectively, while the nacelle components were delivered using our 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 km route. Undertaking nighttime deliveries in order to minimise 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 utilised and spread over two nights.

En-route to the wind farm, the drivers had to perform several complex manoeuvres. 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 metre rear projection to simulate the actual blade transportation and 93 metre 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, the team navigated multiple pinch points including a bridge located between pads 3 and 4 several times in the process of delivering the necessary components.

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

Jack Collett, Renewables Director at Collett & Sons Ltd, had this to say

“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.

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 & 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”.

Source: Collett & Sons Ltd.

Also interesting: