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LTC4,000
Growing pains

LTC4,000

Rising high

As demand for more sustainable energy increases, wind turbines grow taller, heavier, and more remote. In an industry that changes rapidly, one thing remains: the importance of generating the first Megawatt quickly.

So Mammoet created the LTC4,000.

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In the sector

The pace of growth in onshore wind is quite staggering. Over the last half decade, power output from wind turbine generators has risen by 100%; hub heights have grown from around 60m on average to over 175m; and each day more sites have open up for development reaching higher into more reliable air flows.

Today, turbines with over 5.5MW are planned, with rotors at more than 160m diameter - and growing. Constant innovation is needed to complete the many challenges brought about by such rapid change.

For example, lifting technologies available in the marketplace are limited to around 160m hub height. Truck-mounted cranes with strengthened lattice booms have been widely used but going beyond this height becomes a challenge.

Building over 160m requires heavy crawler cranes that are not designed for wind farm installations, nor to accommodate the industry’s fast paced schedules. They also have relatively low market availability and global spread.

These heavier lifting machines bring other issues. Extra civil works are required to accommodate crawler cranes’ larger working radius with wider areas to move counterweights, long boom down corridors and lengthy, costly processes to relocate the crane between wind turbine pads. Not to mention the cost of building wider hardstands around each WTG.

This is why tower cranes like the Kroll K1650L have been used for high hub height installations. They are especially useful on projects where the orography of the site is an issue; when aspects like removing trees or preparing pads on mountainous sites becomes too costly.

Their smaller footprints allow for less impactful civil works and faster movement between turbines during installation. They have also benefitted projects where wind conditions are severe, as they have higher wind speed limits compared to truck-mounted cranes or standard crawler cranes. However, even these are not an ideal solution, as they too have a hub height limitation of around 160m, making them ill-prepared for such a changeable market.

WTG installation costs must therefore be considered holistically - by considering the entire installation process at the start of the project, design changes can be made that facilitate later savings. This requires coordination with the crane service provider as well as the civil works designer to ensure the whole installation process is optimized during the development phase.

Mammoet is committed to producing innovative ideas to help our customers succeed and realise their goals. We have therefore designed a solution to install the turbines of the future, reaching over 200m hub height and lifting loads up to 300t.

Carlos Moreno
Carlos Moreno

Carlos Moreno

"Going forward, I am convinced that reaching hub heights beyond 160m and installing much heavier components than today - and doing so cost-efficiently - will be key for the turbines being built over the next few years. I see wind turbines of the future being able to produce over 10MW per unit and reaching hub heights over 200m.

We are committed to producing innovative ideas to help our customers succeed and realize their plans. We have therefore designed solutions to install the turbines of the future, and the LTC4,000 will be part of an ongoing effort to expand the possibilities for wind farms."

Carlos Moreno
Carlos Moreno

In wind, every second counts

Mammoet developed the LTC4,000 to offer the hook height, lifting capacity and optimized relocation process that future wind farms need. The crane will support faster and more efficient construction, offering a crane suited to fast-paced schedules, with less civil work required.

An increased maximum hook height of 220m makes the LTC4,000 well-prepared to install even the tallest turbines. The crane is equipped to handle heavier components with a lifting capacity of 200t at 15m working radius and it is also free standing, so there is no requirement for any tie-in to the wind turbine generator itself.

The LTC4,000 maximizes construction schedules by utilizing an integrated tag line system that enables it to continue operating up to a wind speed of 15m/s, helping developers to generate the first Kilowatt of power faster.

The LTC4,000 can be containerized and is assembled vertically in sections, improving on the laydown area required by crawler cranes significantly – it can be as low as 16m x 16m. With a boom measuring less than 70m, no boom down corridor is needed, further freeing up valuable space on construction sites.

Its smaller footprint and ground bearing pressure of up to 25t/m2 means less civil work is needed, saving time and money. The LTC4000 has been designed with no superlift and the ability to be relocated in a variety of configurations; speeding its movement from installation to installation.

The LTC4,000 was created to offer the hook height, lifting capacity and optimized relocation process that future wind farms need. It will support faster and more efficient construction, lowering the footprint of lifting, reducing the requirement for civil work and lifting a wider variety of WTGs – helping you to reach the first kilowatt faster.

Specifications

Maximum hook height: 220m

Lifting capacity: 200t at 15m radius

Wind speed limit: 15m/s

Assembly area: 16m x 16m pedestal

Ground bearing pressure: 25t/m2

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