Collett and Sons Ltd Delivers 100 Wind Farm Components Including Record Length Blades to Cushaling Wind Farm

Collett & Sons Ltd, leading specialist heavy haulage company based in the UK, has successfully completed the delivery of all 90 wind turbine components to Cushaling Wind Farm in Ireland, working on behalf of Vestas, adding another significant project to their renewables’ portfolio.

Components stored and loaded from the Irish Port of Waterford included:

• 9 Nacelles,
• 9 Hubs,
• 9 power trains,
• 36 tower sections
• 27 blades

The record-breaking 80m long blades were the longest onshore turbine blades ever delivered in the history of the Ireland and the UK.

Once operational, Cushaling Wind Farm will feature nine V162 Vestas Enventus turbines, the first of their kind deployed in either country.

Collett deployed their new Doll Blade Adapter, also known as the clamp and dolly system trailer, to transport the blades. This innovative design by trailer manufacturer DOLL was deployed for the first time in Ireland or the UK.

The trailer provides improved ground clearance, enhanced manoeuvrability and greater stability compared to standard Super Wing Carrier trailers. Collett’s Blade Adaptor requires 2m less space for turning at bends than a 65m platform trailer, ensuring safer driving with high centres of gravity. Despite the impressive total vehicle length of 93m, Collett’s adapter is designed to be universally compatible with blades of up to 120m.

The power train hubs were transported on either 8-axle or 6-axle steerable trailers, and the nacelle components were delivered using their 3-7 Nooteboom clamps. All tower sections (bottom, mid 1, mid 2, and top) were transported using Collett’s 3-7 Nooteboom clamps.

All components, except the blades, were transported directly from the port to the site, following a 295km route taking approximately 10 hours including a rest break along the M4. Night-time deliveries minimised road traffic disruption.  A different route, spread over two nights, was utilised for the blades due to their length and the distance and complexity of the route.

En-route to the wind farm, Collett had to undergo several complex manoeuvres. A 3-point turn was performed at R402 just before Georges Bridge. The junction required several amendments which included tree trimming and a purpose-built turning head created off the R402 to enable the vehicles to drive onto the R401. A second 3-point turn was performed further down the R401 to facilitate entry into the site.

Preliminary works included a test run from port to site, using a Super Wing Carrier trailer with a 11m rear projection to mimic the actual blade transportation and 93m total vehicle length. This identified the requirement of road widening, removal of street furniture and tree trimmings along the route. Temporary infrastructure adjustments, road closures, and contraflow systems were implemented to accommodate the blades’ dimensions. These measures were especially necessary in the Ballinagar and Daingean villages, where blades had to carefully over-sail steel bollards and traffic islands were removed to ensure safe passage. Traffic management and police escort arrangements were made throughout to ensure a safe delivery.

Upon arrival at the site, each component was delivered to its respective pad. Whilst on site, Collett skilfully navigated multiple pinch points including a bridge located between pads 3 and 4 several times in the process of delivering the necessary components.

Collett & Sons’ success in this project was made possible through effective collaboration within the team, strategic planning, advanced logistics and community liaison with councils, and the police, ensuring a smooth execution. This project highlights Collett’s expertise in managing high-profile and demanding logistics projects with precision and professionalism.

Describing the project, Jack Collett, Renewables Director at Collett & Sons Ltd said, “Cushaling was an extremely challenging and technically difficult project, especially managing this size of blades in nighttime delivery conditions. However, we’ve come through the other side and delivered the project successfully which is a tremendous achievement. Our Blade Adapter trailers have been a game-changer in allowing us to transport the longest onshore blades to date on land across Ireland and the UK. We are so proud of our team who are a makeup of individuals that work extremely hard and dedicated to providing a quality service for our customers. I’d also like to extend our gratitude to our partners at ELS for their assistance with permits & pilots for each movement and for their management of the Garda escorts, as well as to Celtic Shipping and the Port of Waterford for their assistance with handling the cargo on the quayside”.

Cushaling Wind Farm represents a significant step in the region’s commitment to renewable energy potentially generating 55MW of energy output to the Irish electricity grid system.

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