Comprehensive analysis of wind turbine installation processes, focusing on production rates, critical lifts, and sequential assembly operations. Based on standard 4.5-6.0MW onshore turbines.

Component Specifications

Component	Weight (t)	Height/Length (m)	Crane Requirement
Foundation	600-800	20-25 (dia)	150t crawler
Tower Sections	70-90 each	20-30 each	600t crawler
Nacelle	80-100	12-15	600t crawler
Hub	35-45	4-6	600t crawler
Blades (each)	15-20	65-75	600t crawler

Installation Sequence Production Rates

FOUNDATION WORKS

Activity	Duration (days)	Team Size	Equipment
Excavation	2-3	6-8	Excavators
Reinforcement	3-4	8-10	Mobile Crane
Concrete Pour	1-2	10-12	Concrete Pumps
Curing	7-14	–	Monitoring

TOWER INSTALLATION

Section	Duration (hrs)	Team Size	Wind Limit (m/s)
Base	4-6	8-10	12
Mid	4-6	8-10	10
Top	6-8	8-10	8

NACELLE AND ROTOR

Component	Duration (hrs)	Team Size	Wind Limit (m/s)
Nacelle	6-8	10-12	8
Hub	4-6	8-10	8
Blades	8-12	10-12	6

Project Timeline (Single Turbine)

Phase	Working Days	Dependencies
Site Prep	5-7	Weather/Access
Foundation	15-20	Concrete Supply
Hardstand	3-4	Ground Conditions
Assembly	4-6	Wind Conditions
Commissioning	3-4	Grid Connection

International Production Examples

EUROPEAN PROJECTS

Location	Turbines	Rate (units/month)	Contractor	Year
UK	45	6-8	Vestas	2023
Germany	60	8-10	Siemens	2022
Spain	35	5-7	Nordex	2023
France	50	7-9	GE	2022

ASIA-PACIFIC PROJECTS

Location	Turbines	Rate (units/month)	Contractor	Year
Australia	40	5-7	Vestas	2023
China	80	10-12	Goldwind	2022
India	55	7-9	Suzlon	2023
Japan	30	4-6	MHI	2022

Wind Turbine Crane Requirements and Assembly Analysis

Main Crane Specifications

PRIMARY LIFTING CRANE

Crane Type	Capacity (t)	Boom Length (m)	Configuration	Wind Limit (m/s)
Liebherr LR1600	600	140-160	Main Boom + Luffer	8-10
Liebherr LG1750	750	140-160	Main Boom + Fixed Jib	8-10
Demag CC3800	650	140-160	Main Boom + Superlift	8-10
Manitowoc 18000	750	140-160	Main Boom + Fixed Jib	8-10

SUPPORT CRANE REQUIREMENTS

Purpose	Capacity (t)	Type	Quantity
Tailing Crane	200-250	All Terrain	1
Assembly Crane	100-150	Mobile	1
Components	80-100	All Terrain	1
Rigging Support	50-80	Mobile	1

Crane Assembly Sequence

MAIN CRANE SETUP

Activity	Duration (hrs)	Team Size	Equipment
Hardstand Prep	8-10	6-8	Dozers/Compactors
Crane Platform	4-6	4-6	Support Crane
Crawler Assembly	6-8	8-10	Support Crane
Boom Assembly	8-10	8-10	Support Crane
Superlift Setup	4-6	6-8	Support Crane

Component Lifting Analysis

TOWER SECTIONS

Section	Weight (t)	Height (m)	Radius (m)	Duration (hrs)
Base	80-90	20-25	22-25	4-5
Mid	70-80	25-30	24-27	4-5
Top	60-70	30-35	26-29	5-6

NACELLE AND ROTOR

Component	Weight (t)	Radius (m)	Height (m)	Duration (hrs)
Nacelle	85-95	28-32	120-140	6-8
Hub	35-45	30-34	120-140	4-6
Single Blade	15-20	35-40	120-140	3-4 each

Crane Pad Requirements

SPECIFICATIONS

Parameter	Requirement	Testing Method
Ground Bearing	260-300 kPa	Plate Load Test
Platform Size	40m × 40m	Survey Control
Levelness	±25mm	Laser Level
Compaction	98% MDD	Nuclear Density

Weather Limitations

OPERATIONAL LIMITS

Operation	Max Wind (m/s)	Visibility (m)	Temperature (°C)
Crane Assembly	12	>50	-10 to +35
Tower Sections	10	>100	-10 to +35
Nacelle Lift	8	>200	-10 to +35
Blade Install	6	>500	-10 to +35