How a 365-metre wind turbine was hauled up inside its own tower
German engineers have built what they say is the world's tallest wind turbine. The clever part is how they got it up there without a crane that could reach 300 m.
This week, a wind turbine at Schipkau in eastern Germany reached its full height of 365 m to the tip of its blades. Its hub, the centre of the rotor, sits about 300 m up. The blade tips are only 3 m lower than Berlin's 368 m TV tower, the tallest structure in Germany.
Why go so high? The wind is stronger and steadier far above the ground. Designer GICON says that doubles the energy a turbine can collect, compared with a normal turbine with the same size of rotor. It expects at least 18 GWh a year from this one, though that has not been measured yet.
The problem is the crane. No ordinary crane can lift a turbine's nacelle (the housing for the generator) to 300 m. So GICON built a steel lattice tower, just under 160 m tall, like an electricity pylon. It then assembled a second, inner tower inside it, close to the ground, with the turbine on top. Steel cables pulled that inner tower up through the lattice at about 9 m an hour, and the whole lift took around 24 hours. The technique, called strand lifting, is common on bridges but new for wind turbines, says the German engineers' association VDI.
The turbine itself is modest: 3.8 MW, with a 126 m rotor. Germany's innovation agency SPRIND paid for it. Official start-up is planned for November. GICON says future versions could carry turbines of more than 7 MW.
Why it matters to youThe energy here comes from height, and height is a structural problem. Lattice design, wind loading, fatigue and heavy lifting are the skills that made this turbine possible.