Three 800-Tonne Liebherr Cranes Assemble the Tallest Onshore Wind Turbines in the World
- Meagan Wood
- 8 hours ago
- 5 min read
30-Second Takeaway
Three Liebherr 800-tonne cranes played a critical role in assembling ten Nordex N175/6.X wind turbines at the Mahlsdorf wind farm in Germany. With 179-metre hub heights and 175-metre rotor diameters, the project pushed lifting limits, requiring advanced boom systems, flexible ballast handling, efficient logistics, and rapid on-site service support.
800-Tonne Liebherr Cranes Erect Next-Generation Wind Turbines
The construction of the Mahlsdorf wind farm demonstrated how modern 800-tonne Liebherr cranes are essential for assembling the next generation of high-capacity onshore wind turbines particularly under tight timelines and challenging wind conditions.
At the end of 2025, an LG 1800-1.0 from Nolte and two LR 1800-1.0 crawler cranes from Hofmann and Neeb erected ten Nordex N175/6.X turbines, part of the Delta4000 series.
Each turbine features:
Rotor diameter: 175 metres
Blade length: 87.5 metres
Blade weight: 30 tonnes
Hub height: 179 metres
Capacity per turbine: 6.8 MW
These specifications place the turbines among the tallest onshore wind turbines in the world.
Larger rotor diameters and increased hub heights allow turbines to operate above ground-level boundary layers, capturing stronger and more consistent wind speeds particularly beneficial in low-wind regions.
High Lifting Demands Require Advanced Boom Systems
As turbine dimensions increase, so do crane requirements. The gearbox alone weighs 83 tonnes net, making it the heaviest single component.
All three cranes were equipped with:
HSL4 boom system
174-metre main boom
18-metre fixed jib
170 tonnes of upper carriage ballast
100 tonnes of suspended ballast
Across the site, nine Liebherr cranes including auxiliary machines worked in coordinated operations.
Flexible Ballast Handling Maximises Productivity
Approximately 400 tonnes of suspended ballast were required to erect the mast.
The VarioTray system significantly improved efficiency. The 300-tonne large ballast pallet can be separated from the remaining 100-tonne pallet within minutes. This reduced downtime during assembly and dismantling and enabled crews to maximise a narrow two-day weather window.
The V-Frame system further enhanced productivity by allowing rotor blades stored at greater distances to be picked up using a larger ballast radius and then installed using a smaller radius without the need for re-stacking ballast.
These efficiencies proved critical when operating within tight seasonal completion deadlines.
Blade Control Systems Enable Lifts in Higher Wind Speeds
To stabilise rotor blade installation, crews used:
A crossbeam from Liftra
The Autonomous Positioning System (APS) from Seasight Solutions
The APS uses two electronically controlled propellers to stabilise and control blade positioning during lifting operations. This technology enables installation in wind speeds of up to 30 km/h.
Erik Piper, crane operator and SPMT operator at Hofmann, explained:
“The LR 1800-1.0 is ideal for assembling the next generation of wind turbines with increasing hub heights and higher masses. The crane is strong enough to work at wind speeds of up to 30 km/h based on the wind load tables.”
He added that without stabilisation systems like APS, crews would be limited to significantly lower wind speeds, increasing downtime.
Minimised Conversion Times and Efficient Transport
Optimising crane conversion times between projects is critical for controlling construction costs.
Hofmann used Self-Propelled Modular Transporters (SPMTs) to move the LR 1800-1.0 without fully dismantling it. The base unit (without tracks) and entire counter jib were transported as a single assembly.
Nolte selected the LG 1800-1.0 over a crawler configuration for logistical reasons.
Jürgen Peters, Project Manager at Nolte, stated:
“We are basically a mobile crane company. Since the LG 1800-1.0 does not require the transport of 70-tonne crawler tracks, it is a better fit for our low-loader fleet.”
Neeb faced additional logistical challenges, relocating its crane within seven days — including dismantling and reassembly — from a previous project in the Black Forest approximately 850 km away.
Ingo Klees of Neeb’s technical field service team noted:
“This achievement was only possible thanks to an excellently coordinated team and a well-thought-out assembly and transport concept.”
Rapid Liebherr Service Ensures Project Continuity
Intensive crane operations inevitably lead to mechanical wear. During the project, a crawler experienced hydraulic pump issues.
Within hours, Liebherr Service was on site. Through coordinated repairs, an additional night shift, and strategic scheduling during adverse weather conditions, the crane was operational in time to maintain synchronised tower assembly.
Rainer Schlesner, crane operator at Nolte, confirmed:
“The excellent and fast service is one of the main reasons why we always choose Liebherr cranes.”
Well Equipped for Future Wind Installations
With increasing turbine heights and component weights, the 800-tonne Liebherr cranes are positioned as a key solution for future wind energy installations.
Advanced boom systems, flexible ballast technology, intelligent blade stabilisation systems, and strong service infrastructure collectively demonstrate how heavy lift technology continues to evolve alongside renewable energy demands.
About Liebherr-Werk Ehingen GmbH
Liebherr-Werk Ehingen GmbH is a leading manufacturer of mobile and crawler cranes, with lifting capacities ranging from 35 tonnes on 2-axle mobile cranes to heavy-duty cranes capable of lifting 1,200 tonnes on 9-axle chassis.
Its lattice boom crawler and mobile cranes offer lifting capacities of up to 3,000 tonnes and are deployed globally across construction, infrastructure, and energy projects.
The Ehingen facility employs approximately 5,000 personnel. In 2024, the plant recorded turnover of €3.19 billion. A comprehensive global service network supports high equipment availability worldwide.
Website: https://www.liebherr.com
About the Liebherr Group
The Liebherr Group is a family-owned global technology company with more than 150 companies worldwide. In 2024, it employed over 50,000 people and generated combined revenues exceeding €14 billion.
Founded in 1949 by Hans Liebherr in Kirchdorf an der Iller, Germany, the company continues to focus on technological innovation and industry-leading solutions across construction equipment and diversified engineering sectors.
Frequently Asked Questions
What cranes were used to assemble the Nordex N175/6.X turbines?
An LG 1800-1.0 and two LR 1800-1.0 800-tonne Liebherr cranes were used to erect the turbines at the Mahlsdorf wind farm.
How tall are the Nordex N175/6.X wind turbines?
The turbines have a hub height of 179 metres and a rotor diameter of 175 metres, making them among the tallest onshore wind turbines in the world.
What is the lifting capacity of the LR 1800-1.0?
The LR 1800-1.0 has a maximum lifting capacity of 800 tonnes and can be configured with various boom and ballast systems for heavy wind turbine assembly.
What technology allows blade installation in higher wind speeds?
The Autonomous Positioning System (APS) uses electronically controlled propellers to stabilise rotor blades, enabling installation in wind speeds of up to 30 km/h.
Why is ballast flexibility important in wind turbine assembly?
Flexible systems such as VarioTray and V-Frame reduce setup time, improve efficiency during weather windows, and eliminate the need for repeated ballast stacking, significantly improving project productivity.nted products and services in a wide range of other areas. The Liebherr Group includes over 150 companies across all continents. In 2024, it employed more than 50,000 staff and achieved combined revenues of over 14 billion euros. Liebherr was founded by Hans Liebherr in 1949 in the southern German town of Kirchdorf an der Iller. Since then, the employees have been pursuing the goal of achieving continuous technological innovation and bringing industry-leading solutions to its customers.
