800 tonne cranes build Mahlsdorf wind farm

Nordex Group has completed its first wind farm featuring the new N175 6.X turbine at Mahlsdorf in Brandenburg, with heavy lift support from three 800 tonne cranes supplied by German contractors.

The project, developed by UKA and Nordex, comprises ten N175 6.X turbines, each rated at 6.8 MW. With a rotor diameter of 175 metres and a hub height of 179 metres, the machines rank among the tallest onshore turbines currently in operation.

To meet the demanding lift requirements, an LG 1800 1.0 from Nolte and two LR 1800 1.0 crawler cranes from Neeb and Hofmann were deployed. All cranes were built by Liebherr at its Ehingen facility. Auxiliary lifting equipment on site was also supplied by Liebherr, bringing the total to nine cranes working in coordination.

The heaviest single component, the gearbox, weighed 83 tonnes net. Each main crane was configured with the HSL4 boom system, featuring a 174 metre main boom and an 18 metre fixed jib. Ballast configuration included 170 tonnes on the upper carriage and 100 tonnes of suspended ballast, with additional ballast used for mast erection.

Flexible ballast handling systems such as VarioTray and V Frame helped reduce assembly times and optimise short weather windows. Contractors also focused on minimising conversion times between sites, using SPMTs to transport large crane assemblies without full dismantling.

Rapid service support proved crucial during the campaign. When a hydraulic pump issue affected one crawler crane, Liebherr technicians responded within hours, enabling the team to maintain the installation schedule.

With increasing rotor diameters and hub heights across the sector, contractors say 800 tonne class cranes are becoming essential for assembling the next generation of high capacity onshore wind turbines.