Part 2 of the 2-part article. Click here to read Part 1.
This article explains how advanced motion control, compliant load securing and certified testing protect wind turbine components, improving safety, reducing crane time and supporting reliable wind farm development in Australia.
Motion Control for Wind Farm Installations
Lifting long and slender wind turbine components requires stability as well as strength. Motion control systems, including engineered lift points, guide mechanisms and controlled tag line systems, help minimise rotation and pendulum movement during installation. This is particularly important in outback Australian wind farm locations where wind conditions can change rapidly. Improved motion control reduces corrective crane movements, lowers crane time and enhances crew safety during complex wind turbine lifts.
Lashing Equipment & Load Securing for Wind Turbine Transport
Transporting wind turbine components across Australia requires certified lashing equipment and compliant load securing systems. Integrated lifting and lashing solutions are essential to prevent transport related damage before components reach site. RUD’s Grade 120 ICE chain systems and lashing equipment provide:
- High strength-to-weight performance
- Certified load restraint
- Reduced risk of blade or nacelle damage
- Compliance with Australian load restraint guidelines
By integrating lifting and lashing equipment into a complete material handling strategy; wind energy operators reduce transport incidents and protect components across the supply chain.
Testing, Certification & Compliance
Compliance and traceability are critical in major wind energy infrastructure projects. Certified lifting and lashing equipment should include:
- Load testing
- Non-destructive inspection (NDT)
- Documented certification
- Full traceability of lifting points and assemblies
Comprehensive testing ensures load paths and fabricated components meet Australian standards before operation. For EPC contractors and project owners, this documentation simplifies audits and strengthens regulatory confidence across wind farm developments.
Planning Wind Turbine Lifting Early
For optimal performance, lifting equipment selection should begin during the wind farm design phase, not just prior to mobilisation. Project planners should:
- Define lift points during engineering reviews
- Engage lifting specialists early
- Confirm certification and compliance requirements
- Plan for spare parts and inspection intervals
- Consider monitoring systems where required
Early coordination ensures lifting and lashing equipment is engineered specifically for each wind energy project, reducing installation challenges and improving long term reliability.
Supporting Australia’s Growing Wind Energy Industry
As Australia’s wind energy capacity continues to grow, so does the need for advanced wind turbine lifting and lashing equipment. Through modular spreader beams, component-specific lifting systems, integrated Grade 120 lashing equipment and certified testing and inspection services, RUD Australia supports wind farms across manufacturing, transport, installation and maintenance.
The result is safer wind turbine lifts, faster project schedules, reduced downtime and lower lifecycle costs, ensuring high value turbine components remain protected throughout their operational life.
Frequently Asked Questions
What chains are used for wind turbine transport?
Certified Grade 120 lifting chains are commonly used for heavy duty load securing during wind turbine transport across Australian wind farms.
How do you ensure lifting compliance in Australia?
Compliance is ensured through load testing, certification, documented traceability and adherence to Australian standards for lifting and lashing equipment.
If you want more details of our wind turbine lifting and lashing solutions, email us or call us on 07 3809 1300.
Article copyright to RUD Australia. This information is accurate at the time of publication, and RUD Australia takes no responsibility for any errors, inadvertent or otherwise.
This is a 2-part article.
Australia’s growing wind energy sector demands engineered lifting and lashing solutions to safely and efficiently handle longer blades, heavier nacelles and taller towers across installation, transport and maintenance.
Delivering safe and efficient wind turbine lifting in Australia requires more than standard rigging gear. It demands engineered lifting equipment, certified lashing systems and technical expertise that protect high value components throughout the wind energy project lifecycle.
Engineering Support Across the Wind Farm Lifecycle
From manufacturing facilities to remote wind farm sites, lifting and lashing solutions must integrate seamlessly.
RUD Australia supports wind energy projects with:
This end-to-end capability ensures continuity between manufacturing, transport, installation and maintenance, reducing risk while improving efficiency across Australian wind farms.
Why Lifting Innovation Matters in Wind Energy
Every wind turbine lift carries risk. Incorrect rigging, unpredictable weather conditions or inadequate planning can lead to:
- Blade or tower deformation
- Extended alignment time at height
- Increased crane hours
- Higher labour costs and project delays
Engineered lifting equipment reduces these risks by aligning beam geometry precisely with designated lift points. Using in-house finite element analysis (FEA), lifting systems can be validated to control bending forces and ensure safe load distribution.
Certified lifting equipment manufactured and inspected to Australian standards minimises downtime, reduces corrective work onsite and offshore and shortens wind farm installation schedules.
Modular Spreader Beams for Wind Turbine Lifting
Modular spreader beams remain central to safe wind turbine lifting. Multi-point lifting reduces bending stress on long components such as blades and tower sections.
Modern modular lifting beams:
- Adapt to different turbine models
- Evenly distribute loads across multiple lift points
- Are validated through engineering analysis
- Can be reused across multiple wind energy projects
This modular approach supports reusability and lowers total lifecycle costs - a key consideration in large scale Australian wind farm developments. Custom lifting beam configurations further ensure correct load paths and safe lifting geometry for specialised turbine components.
Component-Specific Wind Turbine Lifting Equipment
Wind turbine components require precision handling to protect composite blade surfaces, machined interfaces and internal assemblies.
Specialised lifting equipment for wind energy projects includes:
- Blade lifting tools
- Nacelle and hub lifting fixtures
- Generator lifting systems
- Rotor and tower handling equipment
Using purpose designed lifting equipment improves control, protects high-value assets and reduces reliance on improvised rigging methods. This shortens alignment time and enhances safety during wind farm construction and servicing.
Click here to read Part 2 ...
If you want more details of our lifting and lashing solutions for the wind energy sector, email us or call us on 07 3809 1300.
Article copyright to RUD Australia. This information is accurate at the time of publication, and RUD Australia takes no responsibility for any errors, inadvertent or otherwise.
Frequently Asked Questions
What lifting equipment is used for wind turbine installation in Australia?
Wind turbine installation in Australia uses modular spreader beams, blade lifting tools, nacelle lifting fixtures and certified Grade 120 chains to distribute loads safely and comply with Australian standards.
Why are modular spreader beams important for wind farms?
Modular spreader beams distribute loads evenly across multiple lift points, reducing bending stress on long blades and tower sections while ensuring safe wind turbine lifting.
Part 2 of the 2-part article. Click here to read Part 1.
Delivery Stage
RUD's lashing solutions are used to secure wind turbine components during transport. For example, the L-VLBG M36 lashing point is ideal for securing a nacelle.
Jens adds, "When it comes to reliable solutions for safe transport, you can depend on RUD technology. Poor quality load-securing products are the major contributors to accidents in the wind power industry. The cost of a new nacelle or postponing the commissioning of a turbine is costlier than investing in the right load-securing product”. ICE Grade 120 lashings reduce weight while keeping safety paramount. Products such as the ICE-CURT-GAKO ratchet tensioner prevent accidental release, which can happen from vibrations while driving.
Installation Stage
RUD offers custom lifting and handling solutions when installing heavy tower segments and rotor blades. Jens explains, “For lifting and erecting large and heavy tower segments, special attachment points are attached to the flanges of the segment. The RUD T-FRB (FLARIBO) flanged load ring was specially developed for such an application and features a patented thrust bearing washer incorporated into the lateral bearing for 90° loading."
Four FLARIBOs are mounted to the top of the segment and two FLARIBOs to the bottom to erect a tower segment. The segment is then lifted using two cranes and erected in the air. The sling chains move over the deflection rollers of the RUD VIP Chain Block (VCB). The VCB allows load balancing for the segment to be positioned vertically. The flange to flange can then be bolted together. When the four FLARIBOs are removed from the top of the tower segment, the deflection rollers of the VCB prevent the unloaded side of the chain from slipping through and falling.
After the tower is assembled from its individual segments, the next step is to mount the nacelle and hub assembly. "A lifting beam is used to lift the pre-assembled rotor blades for the hub assembly. The lifting beam has two generators and two hydraulic systems, which ensures safe assembly of the hub in the event of a partial failure of the system”.
Operation and Maintenance Stage
It is crucial to ensure personal safety mechanisms are in place while conducting maintenance operations. At such dizzying heights, there is no compromise on risk. The PSA-VRS STARPOINT has been specially developed to secure people by connection with the safety harness.
A RUD PSA-VRS STARPOINT can carry up to two persons, offering the advantage of safe securing of the victim and the rescuer in the event of an incident. The PSA can be rotated 360° and forms a compact securing unit with its special non-removable screw.
“The stainless-steel variant, PSA INOX-STAR, is designed for permanent outdoor use in challenging weather because of its corrosion resistance," says Christiansen.
Decommissioning Stage
Like installation and delivery, the same products can be used during dismantling and removal. For example, the flange load ring T-FRB (FLARIBO) and the VCB can be used to safely lift pipe segments. The L-VLBG M36 lashing load block, ICE-CURT-GAKO ratchet tensioner and ICE 120 lashing chains can be used during loading and transport.
Offshore plant?
Onshore wind turbines require products that are resistant to corrosion and challenging weather. The RUD ROV-HOOK, designed for subsea applications, is the first of its kind that can be operated with only one robot arm of a robot-operated vehicle, handling loads of up to 25 tonnes. Due to its integrated unique locking mechanism, accidental unhooking is impossible, which is a big plus point for safety.
RUD’s products offer safe and efficient applications in a wind turbine's life cycle from planning, production, transport and installation to maintenance and dismantling.
If you are facing challenges in the wind energy industry, RUD can keep your operations safe and efficient. Contact us today for more details on how we can help you.
RUD will be exhibiting at the Crane Industry Lifting Conference - CICA 2023 from 26-28 Oct 2023. Visit us in Booth #27/28 at the Perth Convention Centre to discuss our Lifting and Lashing Solutions for the crane industry.
Article copyright to RUD; this information is accurate at the time of publication and RUD Australia takes no responsibility for any errors, inadvertent or otherwise.
Sources:
This is a 2 part article.
Wind power is currently the cheapest source of large-scale renewable energy, which involves generating electricity from the naturally occurring power of the wind. Wind turbines capture wind energy within the area swept by their blades. The spinning blades drive an electrical generator that produces electricity for export to the grid.
The Australian renewable energy industry accounted for 35.9% of Australia’s total electricity generation in 2022, up from 32.5% in 2021. This is more than double before the boom started in 2017 (16.9%). While there is still a significant way to go if Australia is to meet its ambitious 82% renewables by 2030, there has nevertheless been encouraging progress.
There are currently over 3,000 wind turbines in operation in Australia, generating enough electricity to power over 2 million homes. Some of the largest wind farms in Australia developed over the last few years include the MacIntyre, Coopers Gap and MacArthur.
While the wind energy industry creates jobs and economic opportunities in Australia, employing over 10,000 people and an additional 10,000 jobs by 2030, it faces a lot of operational challenges, such as:
- Logistics and Transportation challenges, including intercontinental sea transport, handling and storage in local ports and transportation from the ports to the installation sites, several of which are in remote areas.
- Installation and Lifting challenges ensure everyone goes home safely from the project every day.
- Servicing challenges (20+ years) including end-of-life turbines and components.
RUD Solutions for the Wind Energy Industry
RUD is a world leader in lifting and lashing and offers a wide range of solutions for the wind energy industry to increase safety and efficiency in the design - manufacturing - logistics - installation and maintenance processes.
Reliability and Safety are Key in the Supply Chain
According to Jens Christiansen, RUD Slings Division Sales Manager for Germany, Austria, and Switzerland, "Logistics already starts with the design. The designer must plan how the component will be assembled, transported on the road or ship, and installed on-site in the design stage itself. As we know, wind energy includes components that are large and very heavy, which makes the job complex. As the leaders in lifting and lashing technology, we offer versatile solutions for all stages in a wind turbine life cycle”.
Where can RUD help?
RUD’s products and services are used throughout the life cycle of a wind turbine, from the design phase to decommissioning.
Idea and Design Stage
RUD lifting points are reputed for top quality, ergonomics and safety in lifting technology and load securing for more than 35 years. We offer more than 700 tested boltable and weldable lifting points in load ranges up to 250t, which meet maximum safety requirements. Our engineers can work with wind turbine manufacturers to design lifting and lashing solutions that meet the specific requirements of each project.
Production Stage
Whether lifting or moving small components or huge rotors, RUD has a solution for every task in the production process. Lifting, handling, or moving during production can be made more efficient using standard products. For example, the VLBG-PLUS Load Ring is suitable for lifting, rotating, and turning operations due to its large load-bearing capacity, excellent material properties (temperature/corrosion resistance) and ideal design. A VLBG-PLUS can be rotated 360° or swivelled 180° in the direction of the load. This makes it extremely easy to hook the sling into place, saving time and money.
RUD has also developed a Tool Mover with a capacity from 2.5 tons to up to 64 tons. RUD tool movers are widely used and accepted safety devices to guarantee the safe rotating and turning of turbines and critical components. Click to read how Enercon, a German wind turbine manufacturer is using RUD Tecdos Tool Mover to lift, move and turn large rotors of wind turbines.
RUD will be exhibiting at the Crane Industry Lifting Conference - CICA 2023 from 26-28 Oct 2023. Visit us in Booth #27/28 at the Perth Convention Centre to discuss our Lifting and Lashing Solutions for the crane industry.
To be continued ...
Article copyright to RUD, this information is accurate at the time of publication and RUD Australia takes no responsibility for any errors inadvertent or otherwise.
Sources:
