Collett & Sons Ltd, the UK-based heavy haulage specialist, has completed a challenging delivery of 90 wind turbine components to Cushaling Wind Farm in Ireland. The project, commissioned by Vestas, marks a landmark moment for onshore wind in the UK and Ireland, featuring the longest-ever onshore turbine blades in the region, each measuring a record-breaking 80 meters. Once operational, Cushaling Wind Farm will showcase nine Vestas Enventus V162 turbines, a first for both countries and a notable advancement for Ireland’s renewable energy goals.
For this ambitious project, Collett leveraged their latest transport technology: the Blade Adapter trailer, developed by DOLL. This high-tech adapter system, also called a “clamp and dolly,” enhances ground clearance, stability, and maneuverability, making it ideal for transporting massive turbine blades. Unlike traditional trailers, which can struggle with high centers of gravity, Collett’s Blade Adapter requires significantly less space to navigate bends—cutting the turn radius by two meters compared to a 65-meter platform trailer. Even with a total vehicle length reaching 93 meters, the Blade Adapter can handle blades up to 120 meters in length, demonstrating impressive versatility and setting a new standard in turbine logistics.
From the Port of Waterford, where all components were stored and loaded, Collett transported nine nacelles, nine hubs, nine power trains, 36 tower sections, and 27 blades to the Cushaling site, navigating a complex 295-kilometer route. The journey included numerous night deliveries, aimed at minimizing traffic disruption and ensuring road safety. Each trip took around 10 hours, including rest breaks, with most components—except the blades—transported directly from port to site. However, due to the blades’ exceptional length, Collett employed a separate, carefully planned route over two nights to ensure a safe delivery.
Transporting such massive components required meticulous planning and specialized equipment. The hub assemblies and power trains were moved on 8-axle and 6-axle steerable trailers, while the tower sections were transported using Collett’s 3-7 Nooteboom clamps. The sheer size and weight of the blades necessitated a trial run with a Super Wing Carrier trailer to gauge clearance and anticipate potential challenges along the route. Adjustments included temporary road widening, the removal of traffic islands, and tree trimming to accommodate the 93-meter vehicle length. In towns like Ballinagar and Daingean, additional contraflow systems and traffic management measures ensured the blades could safely pass over obstacles like steel bollards.
Among the project’s logistical challenges, Collett’s team had to navigate multiple pinch points, including a bridge between pads three and four. Complex maneuvers, such as three-point turns on narrow roads, required careful execution, with police escorts and road closures along the way. Temporary infrastructure adjustments were implemented in several locations, while local councils and the police worked closely with Collett to ensure minimal disruption and safety.
Jack Collett, Renewables Director at Collett & Sons Ltd, emphasized the technical demands of this project, especially with the unprecedented blade length and the need for nighttime deliveries. “Cushaling was an extremely challenging and technically difficult project, especially managing this size of blades in nighttime delivery conditions,” he noted. He praised the effectiveness of Collett’s Blade Adapter trailers, which were “a game-changer” in enabling the transportation of such long blades across both the UK and Ireland. Collett extended gratitude to their partners, including ELS for permit and pilot support, Garda escorts, and Celtic Shipping and the Port of Waterford for their assistance with handling the cargo at the port.
Cushaling Wind Farm represents a significant milestone for Ireland’s commitment to renewable energy, with the turbines expected to contribute up to 55 MW to the national grid. This project highlights Collett & Sons’ expertise in managing high-profile logistics with precision and underscores their position as leaders in renewable energy transportation.
