Innovation
PROJECT SCOPE:
The Flyers Creek Wind Farm consisted of 38 GE 3.8-137 wind turbine generators. ARES transported all wind turbine components from Port Kembla to site, a distance of 420km one way. Our scope also included offloading our own trucks and setting the turbine components down next to the turbine foundations, ready for the installation cranes to lift them into place at a later date, as well as transporting the project’s 120-ton main transformer to the wind farm substation.
Transported all components for 38 GE turbines across the 420-kilometre route from Port Kembla to Flyers Creek Wind Farm in central NSW. The scope covered port operations, regional heavy haulage, transformer transport and precise offloading at each turbine foundation.
Careful coordination kept almost 400 components moving through congested storage areas, regional town centres and a circuitous route around the Blue Mountains. Integrated transport and cranage capabilities supported safe, efficient delivery from vessel discharge through to final positioning on site.
Almost 400 turbine components arrived at Port Kembla across five shipments while the port managed a major backlog of imported vehicles. Close coordination with terminal operator AAT and the use of overflow areas kept the cargo organised and accessible.
With no bypasses available, oversized loads travelled directly through Boorowa and Cowra. Blades moved during the early morning, while towers travelled by day with drivers, pilots, spotters and police escorts managing traffic and roadside obstacles.
A 120-tonne main transformer required transport from Port Kembla to the wind farm substation at short notice. Permits were secured within one week before the transformer completed the journey using a specialised eight-axle platform trailer.
Turbine components were positioned beside their foundations in preparation for installation. A 200-tonne assist crane provided the strength and manoeuvrability needed to unload components, including 100-tonne nacelles, within the restricted turbine hardstand areas.
Cargo Carried
Each turbine stands 180m tall (base to tip), has 6 tower sections and produces 3.5MW of green power.
Components were on the road between February and August 2020.
The journey took around 5-6 hours, including slowdowns and fatigue breaks.
These include turbine components, towers, blades, transformers and containers.
ARES have set the bar high with their ability to be self-efficient with both transport and cranage with exceptionally high HSE and Quality standards. Communication with all stakeholders at both Port and Project site, the management, engineering solutions and ability to be flexible they have demonstrated throughout the project was remarkable. I would highly recommend ARES and looking forward to working with them on future projects.