Wind Power Construction Process – From Survey to Complete Installation

In the era of renewable energy development, wind power has become a key energy source in Vietnam.
To ensure the success of any wind project, the construction and installation of wind turbines play a decisive role.
With over 15 years of experience in heavy lifting, transport, and installation of over-dimensional equipment,
PLC Heavy Lifting Services JSC is a leading contractor specializing in the Wind Power Construction Process across Vietnam and Southeast Asia.

Wind Power Construction Process

A wind farm project typically goes through six main stages, requiring tight coordination between engineering, equipment, and skilled personnel:

1. Topographic and Geotechnical Survey

• Evaluate soil conditions, wind direction, and ground bearing capacity.
• Determine turbine foundation positions, transport routes, and laydown areas.
• Establish the technical database for detailed design and construction.

2. Engineering Design and Site Preparation

• Design turbine foundations, service roads, crane pads, and laydown areas.
• Strengthen the ground to ensure load capacity for 800–1250 t crawler cranes and modular trailers.
• Plan manpower, equipment, and materials mobilization.

3. Transport of Over-Dimensioned Equipment

• Use hydraulic modular trailers and specialized trucks to transport the tower, nacelle, hub, and blades.
• Conduct detailed route surveys: curve radius, gradient, bridge capacity, clearance.
• Develop a transport plan with a risk assessment and control diagram.

4. Turbine Foundation Construction

• Fabricate and install rebar, grounding system, and anchor bolts.
• Cast concrete according to design standards and test compressive strength.
• Ensure alignment precision within ±5 mm at anchor bolt clusters for tower installation.

5. Tower, Nacelle, and Blade Installation

• Deploy 800–1250 t crawler cranes (main) and 150–300 t assist cranes.
• Sequentially lift tower sections, nacelle, hub, and blades following technical procedures.
• Supervised strictly under EN, OSHA, and TCVN standards.

6. Electrical Connection, Testing, and Handover

• Install underground cables, substations, and SCADA systems.
• Calibrate sensors, perform test runs, and hand over to the owner for operation.
• Complete as-built documentation and commissioning reports.

Main Equipment in the Wind Power Construction Process

Selecting the right equipment is a decisive factor in the entire process. PLC’s engineering team carefully studies each project’s heaviest and tallest components — including nacelle weight, blade length, hub height, terrain, and weather conditions — to propose the most optimal lifting and logistics solutions.

1. Crawler Cranes

• Turbines < 3.5 MW: 600 t crawler crane.
• Turbines 5–6 MW: 800 t crawler crane.
• Turbines > 6.25 MW: 1250 t or 800 t with twin-boom/superlift configuration.

2. Assist Cranes

• 100 t: Cost-effective but limited load range.
• 150 t: The most popular option for turbines above 5 MW.
• 250 t: More flexible and safer, though at higher cost.

3. Mobile Cranes at Turbine Pads

• Typically one pair of 150–200 t mobile cranes for unloading and shifting equipment between turbine pads.
• Combination of 150T and 200T ensures both flexibility and efficiency.

4. Specialized Vehicles and Rigging Equipment

• Internal logistics trucks for tower, hub, and blade movement between pads.
• Service trucks and boom trucks for technical support and logistics.
• Specialized lifting and torque tools: spreader bars, slings, shackles, winches, hydraulic jacks, torque wrenches, load cells, wind sensors, and safety cameras.

PLC’s Wind Power Construction Experience

Over the past 15 years, PLC has successfully completed numerous major wind power projects across Vietnam and Southeast Asia. All projects were delivered on schedule, with top safety and quality standards, meeting every requirement from international EPCs and project owners.

PLC Commitments

1. Absolute Safety – Our Top Priority

Before each work shift, PLC conducts a Toolbox Meeting to inspect crane, sling, shackle, spreader bar, and lifting system conditions, wind speed, ground stability, and actual load weight. Only after all checks are marked “Safe for Operation”, the lifting work begins.

2. Professional and Certified Team

PLC’s engineers, riggers, and signalmen are internationally certified and regularly collaborate with GE, Vestas, Enercon, Goldwind, and Envision. They master lifting signals, coordination, and emergency handling under strong wind and complex terrain conditions.

3. Legal Compliance – Inspection & Maintenance

• All lifting equipment is periodically inspected by licensed safety inspection agencies.
• Maintained as per OEM standards and international regulations.
• Each device has a QR code tracking inspection, maintenance, and operation history.
• Pre-shift on-site checks are performed; equipment operates only when confirmed “Ready to Use”.

4. Optimized Progress – Controlled Cost – Assured Quality

PLC synchronizes its transport, crane, and installation teams, maintains standby equipment on-site, and tracks each turbine’s progress via digital reporting, ensuring the best efficiency and reliability for every project.

Conclusion

The Wind Power Construction Process requires seamless coordination between engineering, equipment, and skilled personnel.
With over 15 years of expertise, a professional workforce, and top-tier heavy equipment,
PLC Heavy Lifting Services JSC proudly stands as one of the most trusted partners in Vietnam and Southeast Asia
for wind power construction, installation, and maintenance.
PLC remains committed to delivering safe, efficient, and on-time solutions for every wind project.

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Wind Power Construction Services