Overview
As the demand for wind energy grows, so does the need for specialized lifting solutions to handle massive turbine components safely and efficiently. AFE Crane has developed and fabricated multiple iterations of custom load bars for the wind energy sector, helping customers navigate the complexities of lifting long and delicate turbine blades. One of our most innovative solutions to date is a 180-foot load bar, designed and built to support wind turbine blade handling while maintaining structural integrity and ease of transport.
Project Challenges
Lifting wind turbine blades presents unique engineering challenges. The load bar needed to span 180 feet while maintaining a 4,000 lb capacity, requiring a design that balanced strength with weight efficiency. Additionally, the bar required 13 rigging points and 2 hoisting points to ensure even weight distribution and secure handling. Due to its extreme length, the load bar also needed to be fabricated in a way that allowed for efficient shipping and on-site assembly.
The AFE Crane Solution
AFE Crane engineered a truss-style load bar to reduce weight while maintaining the required load capacity. The design incorporated splice assemblies, allowing the bar to be fabricated and shipped in three separate sections, simplifying logistics and installation. The load bar was equipped with 13 load points for optimal rigging and two hoist hooking points on top to facilitate safe and stable lifts. By leveraging our expertise in below-the-hook lifting solutions, we created a custom tool that met the precise needs of wind turbine blade handling.
Project Execution
The 180-foot load bar was fabricated, assembled, and load-tested in our Cedar Falls, Iowa facility before shipment. Our engineers meticulously verified the structural integrity and performance of the load bar, ensuring it met all safety and operational requirements. By conducting full-scale assembly and testing in-house, we provided the customer with a fully validated lifting solution, minimizing potential on-site issues and expediting deployment.
Conclusion
This custom 180-foot load bar showcases AFE Crane’s ability to design, fabricate, and test innovative below-the-hook lifting devices for the wind energy sector. By integrating a truss format for weight reduction, splice assemblies for ease of transport, and multiple rigging points for secure handling, we delivered a solution tailored to the complex demands of wind turbine blade lifting. At AFE Crane, we continue to push the boundaries of custom lifting solutions, helping our customers solve their most challenging material handling needs.
