Bladelifter at the Kirchhundem project: Precision work in difficult terrain

Transporting blades for wind turbines through Germany’s Rothaar Mountains is an engineering challenge in which every metre counts. Tight bends, steep inclines and limited space leave little room for error. Using a so-called bladelifter, which Volkswind is deploying for the first time, the 75-metre-long blades can be rotated into different positions, allowing the challenging terrain to be traversed safely.

A so-called bladelifter is being used for the first time in Volkswind’s history at the Kirchhundem wind energy project. This specialist technology is being used to transport the rotor blades from a transshipment site through the challenging, topographically difficult terrain to the actual construction site.

The transports are among the most technically impressive phases of the project. With the help of the bladelifter, each of the 75-metre-long rotor blades can be lifted and deliberately tilted while in transit. This makes it possible to negotiate tight bends, steep inclines and restricted spaces that could not be passed with conventional transport vehicles—or only with considerable additional effort.

This flexibility is particularly important in the hilly region around Kirchhundem. The use of the bladelifter makes it possible to use the existing infrastructure and keep interventions in the landscape and road network to a minimum.

The Kirchhundem wind farm comprises a total of five Vestas V150 wind turbines, each with an individual capacity of 6 megawatts. With a rotor diameter of 150 metres, a hub height of 169 metres and an expected output of around 58 million kilowatt-hours, the project will eventually supply electricity to approximately 14,500 four-person households.

Explained briefly: Why are bladelifters used for transport?

The rotor blades of modern wind turbines are now more than 80 metres long. Transporting such components is a particular challenge, especially in hilly or forested terrain.

Bladelifters are used in these situations because they can:

• Actively lift and tilt rotor blades: The blade is hydraulically rotated to navigate obstacles, embankments and tight bends.
• Enable transport on existing roads: Extensive road upgrades or large-scale clearing can often be avoided.
• Increase logistical safety: Critical sections of the route can be travelled in a controlled manner and at a reduced speed.
• Make construction processes more predictable: Even in difficult terrain, transport operations remain manageable in terms of both scheduling and technology.

The use of bladelifters is therefore an important tool for enabling modern wind turbines to be built at challenging sites. A bladelifter is also being used at the Burbach II wind farm, which is currently under construction a few kilometres away.