Transport, Access Roads and Crane

Requirements

Nordex N80/2500, N90/2500, N100/2500

Version gamma

© Nordex Energy GmbH, Bornbarch 2, 22848 Norderstedt, Germany

All rights reserved. Observe protection notice ISO 16016.

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Transport, Access Roads and Crane Requirements

Table of Contents
1 General ........................................................................................................................... 2
2 Weights, dimensions and handling instructions .............................................................. 3
2.1 Nacelle ............................................................................................................................ 3
2.2 Drive train........................................................................................................................ 4
2.3 Rotor hub ........................................................................................................................ 4
2.4 Weights of components on crane hook...........................................................................5
2.5 Transport frames.............................................................................................................6
2.6 Towers N80/2500, N90/2500 ..........................................................................................8
2.7 Towers N100/2500..........................................................................................................9
2.8 Anchor cage ..................................................................................................................10
3 Requirements on the access roads...............................................................................11
3.1 Loads ............................................................................................................................ 11
3.2 Slopes ........................................................................................................................... 11
3.3 Clearance profile on a straight route ............................................................................. 11
3.4 Bends ............................................................................................................................ 12
3.5 Road foundation............................................................................................................12
4 Crane requirements ......................................................................................................13
5 Crane hard standing area ............................................................................................. 13

1 General
All details regarding the transport project must be agreed with all persons involved
beforehand.
Local conditions always define the transport project i.e. the process is always project-specific.
All drawing dimensions in chapter 2 are given in millimeter (mm).

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Transport, Access Roads and Crane Requirements

2 Weights, dimensions and handling instructions

2.1 Nacelle
As a standard procedure, drive train, rotor hub and further exterior assemblies (obstacle
lights, wind measuring instruments, lightning arrester, etc.) are not assembled for nacelle
transport.
The transport frame for the nacelle consists of 4 single feet. They can be used for twist lock
fastening, see chapter 2.5. Otherwise anti-slip mats must be used for transportation.
The nacelle must only be placed on the compacted ground or on the crane mats.
3800

1050

1670
90

400
1370 6980 2400
11070 3500

The coordinates of the center of gravity of the nacelle must be determined not considering
the drive train and the transport frame.

Transport foot
front rear

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 Transport, Access Roads and Crane Requirements

2.2 Drive train

Center of gravity
max. 2990

1470

2260

25
1990 ±30
2990
3500
max. 5190

The rear part of the gearbox with the assembled components is protected by wood lagging.
This protection has been considered for the length measure.

2.3 Rotor hub

The rotor hub is delivered on a transport frame. The transport frame does not protrude on the
sides.

Anti-slip mats must be used for transportation.

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Transport, Access Roads and Crane Requirements

2.4 Weights of components on crane hook

A) Weights for transport - with transport frame
Nacelle
Height (without exterior assemblies) 3.80 m
Width 3.50 m
Length 11.70 m
Weight of „empty“ nacelle approx. 54 t
(without rotor shaft, gearbox)
Weight of drive train only approx. 43.2 t
(rotor shaft, gearbox)

Rotor hub Ø 80 Ø 90 Ø 100

Weight approx. 26.5 t approx. 26.5 t approx. 29 t
Dimensions L x W x H 3.61 m x 3.25 m x 3.39 m

Rotor blades Ø 80 Ø 90 Ø 100

Length 39 44 49 m
Height depending on blade inclination 2.7 to 3.6 m 2.7 to 3.6 m 2.7 to 4.1 m
Transport width 2.42 to 3.2 m 2.42 to 3.2 m 2.42 to 3.9 m
Weight per rotor blade approx. 9.7 t approx. 10.9 t approx. 10.5 t

Switch cabinet (Bottombox)

Dimensions L x W x H 2.8 m x 1.2 m x 2.4 m
Weight approx. 2.7 t

B) Weights for erection - without transport frame

Nacelle
Height (without exterior assemblies) 3.63 m
Width 3.50 m
Length 11.70 m
Weight of „empty“ nacelle approx. 53 t
(without rotor shaft, gearbox)
Weight of drive train only approx. 41.5 t
(rotor shaft, gearbox)
Weight of complete nacelle approx. 94.3 t
(without rotor)

Rotor hub Ø 80 Ø 90 Ø 100

Weight approx. 25 t approx. 25 t approx. 27.5 t

Rotor blades Ø 80 Ø 90 Ø 100

Dimensions as specified above, under A)
Weight per blade approx. 9.0 t approx. 10.2 t approx. 9.8 t
Complete rotor approx. 53 t approx. 57 t approx. 58 t

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Transport, Access Roads and Crane Requirements

Switch cabinet (Bottombox)

As specified above, under A)

Transformer
With transformers installed in tower the transformer substation is omitted.
Individual components per wind turbine:
Transformer approx. 8.6 t, L x W x H: 2.6 x 1.3 x 2.54 m
Medium voltage switchgear approx. 1.0 t, L x W x H: 2.0 x 1.0 x 2.0 m
Transformer substation
In terms of time schedule, building of the transformer substation and wind turbine erection
are carried out independently.
For precise dimensions and weights please refer to the manufacturer. Values may vary
even within a wind farm depending on design/variants and scope of supply.
The following values can be found:
Length 3.3 to 7.0 m
Width 2.5 to 3.0 m
Height 2.7 to 3.9 m
Weight (incl. transformer etc.) 15 to 31 t

2.5 Transport frames

Transport frame Weight
Nacelle transport frame approx. 0.6 t (2 x 160 + 100 kg)
Transport frame - drive train approx. 1.7 t
Hub transport frame approx. 1.5 t
Transport frame - rotor blade (root/tip) approx. 150-400 kg/50-600 kg
Depending on method of transportation
Transport beams - switch cabinet are fitted to the cabinet and remain there

Nacelle transport frame

Front bearing surface: 400 x 400 mm
Rear bearing surface: 500 x 400 mm
Load per front foot: 16 t
Load per rear foot: 12 t
The screws for fastening the nacelle are part of the transport feet and must be returned to
Nordex together.

Transport foot
front rear

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Transport, Access Roads and Crane Requirements

Transport frame - drive train

Support piece
for gearbox
1357

3500 2260

For return transport, up to 3 drive train transport frames can be stacked, including the base
up to 4. The bearing shells remain assembled.
290
2227

Base required

760
5780

Transport frame—rotor hub

The transport frame can be stacked and screwed together for return transport.

720
500

755

30
00

2066 3680

The round wood plate must also be returned if not damaged.

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Transport, Access Roads and Crane Requirements

2.6 Towers N80/2500, N90/2500

Hub Height 60 m 70 m 80 m 80 m 100 m

Type of Tower tubular MT tubular MT tubular MT tubular MT tubular MTR

N80/2500
N80/2500 N80/2500
DIBt 3
IEC 1a NVN 1a/IEC 1a
N80/2500 N90/2500 LS
Classification
IEC 1a N90/2500 LS DIBt 2/IEC 3a
N90/2500 HS N90/2500 HS
DIBt 3/NVN 2a
IEC 1b IEC 1b
IEC 2a

Total Weight t 111.2 143.9 172.1 190.2 258.2

1. Tower section
(bottom)
Length m 11.49 22.43 16.51 16.51 13.68
Diameter flange m 4.3 4.30 4.30 4.30 4.30
Diameter bottom m 4.04 4.04 4.04 4.04 4.05
Diameter top m 4.02 4.02 4.03 4.03 4.04
Diameter flange m - - - - 4.30
Weight t 35.9 66.3 56.1 63.8 62.4
2. Tower section
Length m 23.76 22.82 20.86 20.86 16.95
Diameter flange m - - - - 4.30
Diameter bottom m 4.02 4.02 4.03 4.03 4.03
Diameter top m 4.02 4.02 4.02 4.03 4.03
Weight t 46.1 46.7 52.6 58.2 59.2
3. Tower section
Length m 21.66 21.66 17.88 17.88 20.86
Diameter bottom m 4.02 4.02 4.02 4.03 4.03
Diameter top m 2.96 2.96 4.02 4.02 4.02
Weight t 29.2 30.9 34.2 36.9 58.4
4. Tower section
Length m 21.66 21.66 23.80
Diameter bottom m 4.02 4.02 4.02
Diameter top m 2.96 2.96 4.02
Weight t 29.2 31.3 47.7
5. Tower section
Length m 21.66
Diameter bottom m 4.02
Diameter top m 2.96
Weight t 30.5

• Due to the applied transport means, the transport height is 7 cm greater than the tower
diameter.
• The lifting tackles have a height of 15 cm each. Thus the tower sections become longer.
• Please allow changes in the weight of ±2 %.
• The centers of gravity deviate from the center of tower sections by approx. 5 %.

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Transport, Access Roads and Crane Requirements

2.7 Towers N100/2500

Information on tower R80 m MT IEC 3a (3ed) available on demand.

Hub Height 100 m

Type of Tower tubular MTR

N100/2500
Classification
DIBt 2/IEC 3a

Total Weight 296.7

1. Tower section
(bottom)
Length 12.73
Diameter flange 4.30
Diameter bottom 4.06
Diameter top 4.05
Diameter flange 4.30
Weight 74.3
2. Tower section
Length 17.91
Diameter flange 4.30
Diameter bottom 4.04
Diameter top 4.04
Weight 70.8
3. Tower section
Length 20.86
Diameter bottom 4.04
Diameter top 4.03
Weight 67.0
4. Tower section
Length 23.80
Diameter bottom 4.03
Diameter top 4.02
Weight 52.3
5. Tower section
Length 21.66
Diameter bottom 4.02
Diameter top 2.96
Weight 32.3

• Due to the applied transport means, the transport height is 7 cm greater than the tower
diameter.
• The lifting tackles have a height of 15 cm each. Thus the tower sections become longer.
• Please allow changes in the weight of ±2 %.
• The centers of gravity deviate from the center of tower sections by approx. 5 %.

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Transport, Access Roads and Crane Requirements

2.8 Anchor cage

The anchor cage consists of:
Number Dimensions Weight
Name
of parts maximum maximum
Load spreading 2
outside ∅ 4550 mm approx. 3.1 t
plate
Anchor plate 2 outside ∅ 4450 mm approx. 1.7 t
Anchor bolts 160 L = 3450 mm approx. 6.0 t
Washers, nuts and other small parts approx. 0.4 t
The weights can differ a little depending on the tower.
The anchor cage can be delivered in single parts or mounted in 2 parts depending on the
project. The complete anchor cage, including transport supports weighs approx. 10 t.

The anchor cage of N100 R100MTR consists of 200 anchor bolts and has larger dimensions.
Number Dimensions Weight
Name
of parts maximum maximum
Load spreading 2
outside ∅ 4675 mm approx. 4.8 t
plate
Anchor plate 2 outside ∅ 4550 mm approx. 3.1 t
Anchor bolts 200 L = 3450 mm approx. 7.5 t
Washers, nuts and other small parts approx. 0.4 t
The complete anchor cage, including transport supports weighs approx. 14.5 t.

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Transport, Access Roads and Crane Requirements

3 Requirements on the access roads

To avoid problems during the erection of the wind turbine, the following minimum
requirements to the access roads are to be met under normal soil conditions:

3.1 Loads
For each wind turbine the access road must be capable of supporting the following loads:
Vehicles:
- Approx. 50 concrete and construction vehicles, up to 70 vehicles for hybrid towers
- 12 to 20 heavy trucks for crane erection, depending on hub height
- approx. 10 to 13 heavy trucks with turbine components
(3 to 5 tower sections, 3 rotor blades, 3 for nacelle, rotor hub and drive train,
2 for switch cabinet (Bottombox), small parts and erection container)
- max. length: 57 m
- required free height: 4.40 to 5.90 m depending on the method of transportation
- div. construction vehicles
Weight of vehicles:
- max. load per axle: approx. 12 t
- max. overall weight: approx. 165 t

3.2 Slopes
In the case of surfaces as described in section 3.5, slopes must not exceed approx. 6 %. If it
does, please contact Nordex. Steeper slopes may require an extra traction engine, the
additional length must be considered.
Side inclination: maximal 2 %

3.3 Clearance profile on a straight route

For all hub heights
H Clearance height 4.40 to 5.90 m, depending on method of
transportation
W Clearance width 4.50 m

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Transport, Access Roads and Crane Requirements

3.4 Bends
For all hub heights
R1 Inside radius bend 35 m
R2 Inside radius of obstacle-free area 50 m
R3 Outside radius of obstacle-free area Determined by the protruding length of the rotor
blade
The marked area (- - -) must be free of all obstacles, that is, trees, buildings, masts, etc.

min. 8 m

R1

R3 R2
min. 4.5 m

3.5 Road foundation

Example of a cross-section of an access road

3. Top layer compacted, ballast, 15 to 25 cm

Geomembrane as separation 2. Bed compacted, gravel, 15 to 30 cm
layer 1. Base compacted, 30 to 100 cm

30-100 cm 30-55 cm

Subsoil

min. 4.5 m

• Access roads built as compact gravel road, if required with hydraulic or asphalt bond
• Structure from bottom to top:
1. Base compacted, 30 to 100 cm depending on site position and subsoil
geomembrane as separation layer against erosion
2. Bed compacted, gravel, 15 to 30 cm, depending on material used
3. Top layer compacted, ballast, 15 – 25 cm, depending on material
• Instead of gravel, bed and top layer may be made of breakage material (free of all
demolition waste)
• All layers and the subsoil must be compacted using proper machinery allow for heavy
loads

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Transport, Access Roads and Crane Requirements

• Even road surface

• Sound drainage for all access roads must be guaranteed (cross slope of 2 to 3 %).
Sound water piping e.g. in the lateral trenches or under access road junctions must be
guaranteed in order to avoid undermining, erosion, cavitations and landslips
• Before starting road construction a project- and site-specific design/execution plan for the
access roads must be created In the course, the detailed requirements specified by the
structural engineer, geotechnical engineer/surveyor and by Nordex must be fulfilled
• Access roads and crane hard standing areas must remain accessible under every
possible weather condition and over the entire construction time.
• Crawler cranes require special travel and access roads. Track width of up to 12 m might
be necessary.

4 Crane requirements
A main crane and an auxiliary crane are required. The auxiliary crane must change its
position several times before, during and after the wind turbine erection.
• The required hook height is: Hub height + 10 m
• Main crane radius min. 15 to 30 m, depending on crane type
• Auxiliary crane radius min. 6 to 12 m, depending on crane type

Rotor hub height 60 m 70/80 m 100 m 120 m 140 m

Main crane
- Maximum hook load 54.0 t 67.0 t 74.5 t 57.0 t 58.0 t
- Maximum hook load at hub height 54.0 t 58.0 t 58.0 t 57.0 t 58.0 t
Auxiliary crane
Required hook load 20 t 35 t 40 t 30 t 30 t

5 Crane hard standing area

• The crane hard standing area is to be planned and laid out according to the site-specific
conditions and crane requirements.
• The crane hard standing area must withstand the soil pressure of the crane supports.
The soil pressure depends on the maximum weight of the components and the size of the
crane used (mobile crane, crawler crane).
• The entire crane hard standing area must be level (maximum gradient 1 %).
• If the crane hard standing area is more than 1.5 m lower than the foundation top edge,
sufficient hook height must be provided.
• The erection and working area of the crane must be free of obstacles which might impair
the erection and operation of the crane (see following drawings). The length of the rotor
blades and the space for the star assembly must be considered for crane operation.
• The transformer substation must not be placed on the crane hard standing area or the
assembly area of the crane jig.
• To protect the wind turbine from contamination, one foundation access and the ground
must be sealed and covered with gravel to ensure that the surface is dry and clean.
• An approx. 2 m wide walkable working space must be provided directly around the
foundation.

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Transport, Access Roads and Crane Requirements

• The nacelle must only be placed on the crane hard standing area or on the crane mats.
• A clear area for assembly of the crane jib is required for lattice cranes. The length of this
area is hub height + 10 m. The auxiliary crane must be free to move parallel to entire
length of the crane jib. Crane hard standing areas of 10 x 10 m each must be provided at
the third points of the assembly length (see following drawings).
• Example 1 shows the crane hard standing area - including storage areas - when the
delivery of the parts of the wind turbine is not time-critical. The final layout for the specific
site must be planned after the site has been inspected.
• Example 2 shows the crane hard standing area with the minimum requirements. The
area that is required for the temporary storage of the tower sections and the rotor blades
is not included in example 2. This example with incur higher transport costs. The final
layout for the specific site must be planned after the site has been inspected.
• In addition to the examples shown above, a clear area for assembling the rotor (star
arrangement) is also required. This area depends on the local conditions and therefore
Nordex has to be consulted before any action is taken.
• Space for at least 2 Nordex erection containers must be provided (power generator,
tools). Further space must be provided for one Nordex material container to be able to
store material, rubbish skip, cabins, construction vehicles, etc.
• The access roads to the wind turbine must always be kept free for ambulance and rescue
vehicles.

We expressly point out that all values are to be regarded as standard values only.

Further transport instructions can be requested from Nordex.

The lay out of access roads and hard standing area depends on the specific
transportation and erection method.
- The lay out must be individually for each site.
- Depending on the site different variants are possible.
- Transport weights may also vary with the erection site.

The exact design of access roads, crane hard standing areas and assembly areas
must be agreed with Nordex prior to start of construction.

Improper design or lay out of access roads and crane hard standing areas can cause
considerably higher logistic and erection costs at a later stage.

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 Example 1: Minimum requirements to the crane hard standing area with storage areas for 4 tower sections and rotor blades
for an S77 wind turbine with a hub height of 80 m
This sketch is only 9m
exemplary and must 2 Nordex erection containers
15
be modified for each m 1 rubbish skip

K0801_011803_EN
single site
individually.

15,5 m
5 Optimized geometry of the
crane hard standing area
4
3 17 m
Even surface for
the assembly of
2 Auxiliary crane the crane jig
Transport, Access Roads and Crane Requirements

17 m

22,5 m
max. 150 m

Working space 4m
m
15-30
68 m
4,5 m
24 m

Revision 02, 2009-12-04

10 x 10 m

Main crane Access road

12 m

Liebherr LTM 1500 (500 t)

2 erection areas for
Variable radius
Telescopic jib 47.3 m
the auxiliary crane
3m 3m for the assembly of
Lattice jib 42 m
33,5 m the crane jig
Auxiliary crane
Liebherr LTM 1200 (200 t)
Variable radius Crane area with assembly and storage area: approx.: 1600 m2 (1750 m2)
Telescopic jib 60 m

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 Example 2: Minimum requirements to the crane hard standing area without storage areas
for an S77 wind turbine with a hub height of 80 m
This sketch is only exemplary and
must be modified for each single
site individually.

K0801_011803_EN
Optimized geometry of
2 Nordex erection containers the crane hard standing
1 rubbish skip area

25 m Rotor hub

Drive train Even surface for

the assembly of
Nacelle the crane jig
Transport, Access Roads and Crane Requirements

25 m
max. 150 m

Working space 4m
m
15-30
45 m
4,5 m

Revision 02, 2009-12-04

10 x 10 m

Main crane Auxiliary crane Access road

Liebherr LTM 1500 (500 t)
2 erection areas
Variable radius
Telescopic jib 47.3 m
for the auxiliary
Lattice jib 42 m crane for the
assembly of the
Auxiliary crane crane jig
Crane area with assembly and storage area: approx.: 875 m2
Liebherr LTM 1200 (200 t)
Variable radius
Telescopic jib 60 m This variant will incur higher logistics costs

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