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Posted by Brajeshwar 9/13/2025

Wind turbine blade transportation challenges(spectrum.ieee.org)
106 points | 143 comments
mjd 9/13/2025|
This reminds me of an excellent series of lectures I once attended about how you can't have practical skyscrapers without inventing the elevator, you can't have practical automobiles without inventing the windshield wiper, and you can't have practical electric lighting without inventing a whole lot of power generation and distribution technology, or efficient vacuum pumps.

Every big invention depends on hundreds or thousands of other ones you don't hear as much about.

JumpCrisscross 9/14/2025||
> you can't have practical electric lighting without inventing a whole lot of power generation and distribution technology

Didn’t lighting cause power generation and distribution?

ACCount37 9/16/2025|||
Before there was technology for power generation and distribution at scale, "you can use electricity to make light" was a mere curio. Fit to be showcased at fairs, but not something that could be put to practical use.

The first arc lights were made in early 19th century - not long after the invention of voltaic pile made electric power readily obtainable in a lab. But it wasn't until late 19th century that arc lights began to be used as street lights. Why?

Because dynamos and alternators didn't exist in early 19th century. They only became usable for industrial power generation in the late 19th century.

Only when both power generators and arc lights were viable, electric lighting became practical. And electric lighting becoming practical has, in turn, caused electric power to be deployed at an ever-increasing scales, and spurned further investment into electric light, generators and transmission line technology. The invention of incandecent lights fit for household use and the war of the currents were both downstream from better power generation technology.

LargoLasskhyfv 9/17/2025|||
> The first arc lights were made in early 19th century

Possible objection: https://en.wikipedia.org/wiki/Dendera_light#Fringe_interpret...

koverstreet 9/17/2025||
That was good for a chuckle
jasonwatkinspdx 9/17/2025|||
Well also, at least in the US, electric lighting had to be better than gas before it took off. My 1905 house still has pipes for gas lighting in the ceilings.
zdragnar 9/16/2025||||
Sure, but it starts with the impractical version to kick off the other side.

The hearthstone house demonstrated the value of a central power source homes could draw from. The electric lights at the time were not much better than candles in terms of output, but it generated interest enough to get more people on board.

Now, electric lighting is present everywhere, and a practical solution for all but mass agriculture (where the sun remains more efficient).

amflare 9/16/2025|||
You need to be able to distribute power to an area more than once
CGMthrowaway 9/16/2025|||
> you can't have practical skyscrapers without inventing the elevator

There are a ton of apartments in China, Hong Kong and Singapore exceeding 10–20 floors or more without a single functional elevator. Skyscrapers have more to do with steel framing technology than peoplemoving. Regardless, elevators have existed from 200BC and you can see one in the movie Gladiator

>you can't have practical automobiles without inventing the windshield wiper

Streetcars operated for 20+ years at speeds up to 30mph with no wipers. You would just open one half of the windshield. Or use water-repellent glass coatings (similar to today)

rjdj377dhabsn 9/17/2025|||
I really doubt there are many apartments even close to 20 floors without an elevator.

I've traveled a lot and stayed in many old buildings in Asia, but I've never seen one with more than 6-7 floors without an elevator.

gaoryrt 9/17/2025||||
I live in China, and the only building I know that has more than six floors but no elevator is in Chongqing, because it has another walk-in entry in the middle. The vertical distance between the entry and the destination is still fewer than six floors.
MontyCarloHall 9/16/2025||||
>There are a ton of apartments in China, Hong Kong and Singapore exceeding 10–20 floors or more without a single functional elevator

Citation needed. Chinese building codes require elevators for any residential building taller than 6 stories [0]. Hong Kong and Singapore certainly have similar regulations. Unless you're implying that elevators are frequently broken in these countries? Perhaps in poor, rural parts of China, but I'm doubtful this is the case in a wealthy country like Singapore. Indeed, local regulations in both Singapore [1] and Hong Kong [2] require validated monthly maintenance schedules of elevators.

[0] https://codeofchina.com/standard/GB50096-2011.html

[1] https://www1.bca.gov.sg/regulatory-info/lifts-escalators/lif...

[2] https://bestpractice.emsd.gov.hk/en/lift-and-escalator-insta...

Theodores 9/17/2025|||
I know nothing about this, however, today's codes are not the same as yesterday's codes. From what I understand, plenty of very tall housing blocks were built for factory workers and their families, which now get retrofitted with an elevator, or, as we say in the UK, a lift.

This enables people to stay in their own homes in old age. The lift is external to the building, making it relatively easy to install. The balconies, presumably built for mostly clothes-drying purposes in ye-olden-days, provide the access.

I don't know if this goes to 10-20 storeys, I am just chiming in because, yes, there were many high rise buildings without lifts and our ever-inventive Chinese friends have worked out a solution.

In sunny Scotland we have what non-Scottish people call 'apartment blocks' (closes) and some of these go up six storeys with no lifts. Moving house into one of these is fun, as you can imagine. You can get your steps in carrying 25Kg+ for half of your steps, to feel like you have just completed some type of marathon. On the positive side, you are unlikely to be robbed of everything, once you have moved in.

As for fire, this means lots of doors. You might have four doors to work with, two sets on the ground floor and two more on your own floor. These doors make the effort truly Herculean since you can't wedge them all open.

More generally, what amazes me about lifts in the UK is that there is a general lack of redundancy. Recently I had to go across the country by train with a bicycle and two massive rucksacks full of stuff. There were four connecting trains I needed to get. This would have been 'easy enough' if the lifts had been working. They were not working. Had there been two lifts per station then one could be out for maintenance, but no.

vkou 9/16/2025||||
Even the USSR required elevators for buildings 6+ stories. (Which is why Khrushchyovkas were all 5 stories.)
SanjayMehta 9/16/2025|||
https://news.cgtn.com/news/776b6a4e79677a6333566d54/share.ht...
RandallBrown 9/16/2025||||
I would bet most of those skyscrapers at least used some sort of elevator in their construction, even if there's only stairs for the occupants.

Streetcars aren't really what I would think of as a "practical" automobile today since you can only take them on predefined routes.

Dylan16807 9/16/2025||
Pulleys and cranes will easily do everything you need for construction. Elevators aren't even that good for construction, because so much needs to be built to get them working.
jagged-chisel 9/17/2025||
Where is the line between “a pulley and a platform” and “an elevator”?
vishnugupta 9/17/2025||
I guess it’s the ability to arrest a sudden drop.
devoutsalsa 9/16/2025|||
Imagine living on the 20th floor or higher and having a broken ankle.
pstuart 9/17/2025|||
Which in turn reminds me of the excellent series Connections, by James Burke.

It's science and inventions all the way down ;-)

renox 9/17/2025||
> you can't have practical automobiles without inventing the windshield wiper

Sure, but remember that some wipers were "hand activated".

Kaibeezy 9/13/2025||
Were we not getting airships for this purpose? The ones with a butt?

A diagram comparing it to the 747s and oil tankers mentioned in the text would have been appreciated.

OK, looked it up. 108m v 72m. Kvikk diagram, pretty much to scale:

       ,    ||
   WR  ============
       ‘    ||

       ,  \\
   747 ========
       ‘  //
brikym 9/17/2025||
Here is my armchair engineering design. The blades are already wings so they get bolted on and become the wings of the plane and can rotate (or add canards if that's too hard). The engines are at the back.

          \
         ||
         ||
         ||
         ||
         ||
         ||
         ||
    \    ||
    ==   ||   \
    ============>
    ==   ||   /
    /    ||
         ||
         ||
         ||
         ||
         ||
         ||
         ||
          /
But then how does it get back home? Attach some 70m blades as wings.

What about the asymmetry of the blades? You can't have two blades from the same wind turbine as one would have the leading edge facing backwards. Every second wind turbine would have to rotate in the opposite direction for this to work.

It would probably work as well as da Vinci's helicopter but it's an interesting thought experiment.

antod 9/17/2025||
Another problem is that the blade are twisted like propeller rather than straight like a wing.

Which then leads to.... Why not a giant helicopter? Then you don't need to worry about the symmetry.

adrianN 9/17/2025|||
I would love to see the math on how fast you'd need to spin the blades to lift the engine capable of spinning them. In normal operation they spin quite slowly, but due to their lengths the tips reach some ludicrous speeds.
Gravityloss 9/18/2025||||
Exactly. VTOL is also great as you can deliver the blades really close to construction location.

If you installed small props at the tips of the blades, you wouldn't need any torque rotor. I don't know if you still need the variable pitch mechanism or could you lock the blades to one pitch for spin-transport.

Helicopter efficiency is quite terrible though so long distance travel would require constant aerial refueling. I guess you could have a probe in the hub. What could go wrong?

Gravityloss 9/18/2025||
Also, you can even fly a single blade with a small propeller at either tip providing the spinning motion.
viraptor 9/17/2025|||
Or two helicopters carrying the suspended ends of the blade.
ricksunny 9/13/2025|||
(what is a kvikk diagram - google isn’t helping here)
skyyler 9/13/2025||
wild guess: a distorted "quick"
Kaibeezy 9/13/2025||
Brain glitch. I’d just read this - https://www.bbc.com/travel/article/20250909-kvikk-lunsj-the-...
ricksunny 9/13/2025|||
I hope you'll have just coined a new diagram name: Kvikk = simple ASCII diagram that trivially illuminates a technical matter =)

bonus points that mainstream LLM’s can trivially train on them and produce them. =)

Kaibeezy 9/13/2025||
Kool and thx. 72 and 108 divide cleanly by 9, so it’s pretty dang accurate too.
Agentlien 9/17/2025|||
My last name is Kvick (Swedish for quick) and I was delighted to see a variation on it used for something so cool as those diagrams. Please make it a thing.
Kaibeezy 9/17/2025||
Fun. Will try. Perhaps we will hear from some of these people sharing a cognate surname:

  Kvikk    Norwegian
  Kvick    Swedish
  Kvik     Danish
  Kvikur   Faroese
  Kvikur   Icelandic
  Kwiek    Dutch
  Quick    German
  Kwik     Frisian
  Quick    English
Agentlien 9/17/2025||
I at least know that there's a Norwegian chocolate bar called Kvikk and a Danish kitchen design company called Kvik.

In Dutch (which I happen to be fluent in) Kwiek is sometimes used in writing but I've never heard it spoken.

eastbound 9/16/2025||
In height, they have a 24m limit because it’s a common threshold in airports from which special studies must be done. Funny thing: The A380 was 24.1m (its other dimensions also required extra studies, let alone the catering difficulties related to its huge passenger count).

Maybe wind turbines will cause larger planes which will cause an A380 come back ;)

serf 9/13/2025||
seems silly to embrace the design of a plane that is made to move 2 static length blades when even longer blades have been shown to continue the trend of cheaper MW.

the article mentions that 3d printing is a no-go due to the facility needed to print the blade in -- seems like it'd be better to pursue an unfolding container factory with a printer in it and how to transport that thing with conventional craft than to go all-in on a new unproven airframe made for very specific parts.

plus that way the length of the product isn't set in stone, either.

I say this as a total layman -- i'm just taking the articles stated reason for no 3d printing and running with it.

mjd 9/13/2025|
Maybe the idea is: gain expertise in making, loading, flying, and landing 100m planes this year, and try 150m planes next year.
ttoinou 9/16/2025||
“It is faster to make a four-inch mirror then a six-inch mirror than to make a six-inch mirror."

https://wiki.c2.com/?TelescopeRule

comrade1234 9/16/2025||
Genius idea - use the blades as the wings for the plane. They're close enough in shape. :)
xnx 9/16/2025||
Genius-er idea(?) - use the blades to make a helicopter that flies to the site and drives back.
silvestrov 9/16/2025|||
How do you fly back?
Krasnol 9/16/2025||
You don't.

The rest of the plane is the pillar of course.

kashunstva 9/17/2025|||
> They're close enough in shape.

They are lift-producing devices; but I wonder how the inability to change the lift according to flight regime with leading and trailing edge devices would affect the viability of the solution.

ReptileMan 9/16/2025||
with one wing pushing up, the other down it will be a fun flight.
jauntywundrkind 9/16/2025||
Build two windmills that spin opposite directions.

I wish I could source it, it someone told a story of a contract no one could meet for dropping in either some heavy equipment to a site or maybe windmill parts? It was a small site and it seemed impossible to land them take off... The winning bidder for the contract just landed the plane then abandoned it. Not sure what else you'd do if your blades are your plane!

ortusdux 9/16/2025||
It's common to abandon mining equipment at the bottom of the mine, or have tunnel boring machines dig their own tomb. The machines are often custom made, and removal would cost more than their EOL value.

https://www.untappedcities.com/the-200-ton-tunnel-boring-mac...

jollyllama 9/16/2025||
You're gonna build the world's largest airframe from scratch in... (checks notes)... five years?
cjensen 9/16/2025||
Built by a company that has never built an aircraft too. That seems... unlikely.

Seems like if this idea really makes sense, it's exactly the kind of thing the EU would subsidize Airbus to do.

throwup238 9/17/2025||
Especially since Airbus already has experience making the Beluga and Boeing the Dreamlifter.
ahofmann 9/17/2025||
Not only that, we will train people to land this thing on a dirt track, because why not?
rixtox 9/17/2025||
They should call it Blade Runner
1970-01-01 9/16/2025||
What is the full lifecycle plan for the turbine? Is this special airplane to land in the same dirt field that's now a housing development? Are they only pairing these megaturbines with airfields? How exactly will a new blade arrive on-site in 2050?
foota 9/16/2025||
They plan to be able to land the planes in a short distance over rough fields according to the article.
1970-01-01 9/16/2025||
Rough fields tend to grow rough trees.
Jedd 9/16/2025|||
You're coming up with some pretty flimsy reasons that this can't work, and that you believe the people funding, designing, and building these systems haven't contemplated -- such as 'trees'.
ceejayoz 9/17/2025|||
You've reminded me of my favorite letter to the editor I've ever come across.

A while back, we had a whiteout on the highway by the local airport. Someone wrote in to propose - in apparent seriousness - planting trees at the end of the runway to ensure it wouldn't happen again.

1970-01-01 9/16/2025|||
Yes. These trees aren't flimsy obstacles for airplanes. Long term infra funding is very often cut if there isn't an immediate problem. Look around the US and you see power infra literally falling down and sparking wildfires from lack of maintenance.
Jedd 9/17/2025|||
Being about 10,000 kilometres from the US, I can't conveniently look around there.

I expect these guys had 'trees' on their risk register, and have suggested to the site owners to purchase a chainsaw / rent an excavator for a day or two.

Either way, I'm pretty confident on a project the size we're talking here - somewhere upwards of USD $5 billion? - they've probably spent a couple of afternoons pondering logistics.

foota 9/17/2025|||
It doesn't really need to be maintained, it's an active construction site for the time it'll be needed?
margalabargala 9/17/2025|||
Not in the timespan relevant here
bluGill 9/16/2025|||
Nobody is putting wind turbines near housing developments. Wind turbines are noisy up close (you don't want your house next door), and they build to a lower safety standard on the assumption that even in the worst case failure nobody is close enough to be hurt (they still build to a high enough standard that I'm not aware of any failure that could kill someone if they had be there, despite tens of thousands in the world)

They put them in farm fields, you just rent the whole field for the year from the farmer, land the planes, and next year it is framed again. (the farmer will likely be allowed to plant hay in the field and work with you to cut that)

krisoft 9/16/2025|||
> they still build to a high enough standard that I'm not aware of any failure that could kill someone if they had be there

There is a bunch of very energetic windturbine collapses captured on video. In each case someone standing at the wrong spot could have been crushed by falling debris. (Altough i also must admit an overspeeding turbine looks so plainly obviously deadly that anyone with a healthy dose of self preservation would evacuate the danger zone. At least in the cases where we have video of the collapse. There might be a bias to that of course, because nobody would think of filming an unexpected sudden collapse.)

A particularly well documented one is the Hornslet wind turbine collapse.

https://en.m.wikipedia.org/wiki/Hornslet_wind-turbine_collap...

https://youtu.be/jvHBUSSAzyw?si=NDpN-ZgXqPrTavvk

There was this one in Oklahoma: https://reneweconomy.com.au/wind-turbine-collapses-on-calm-d...

This i believe happened in Italy: https://youtu.be/af9Mm5nkNAQ?si=wajCXTCpN19z9okJ

Just a few days ago there was a collapse in Perth: https://www.thecourier.co.uk/fp/news/5330408/blades-perth-av...

There is also a widely shared very dramatic video with horses running away from the turbine just before it collapses. But because i can’t figure out where it happened, and if it even happened, i’m reluctant to include here.

viraptor 9/17/2025||
> would evacuate the danger zone

I wonder how big is the danger zone. The blades seem to come off all at the same time, some to the sides, some up/down. There's quite a lot of kinetic energy there...

ooterness 9/16/2025|||
> Wind turbines are noisy up close...

Citation needed. I toured a wind farm a few months ago, and they were barely audible at ground level.

bluGill 9/17/2025||
The noise isn't loud - but it is constant and annoying to listen to all day.
Goronmon 9/16/2025|||
Are they only pairing these megaturbines with airfields?

That seems like the logical solution. Given the complexities involved overall, a step for "don't build over this patch of dirt" seems relatively achievable.

Onavo 9/16/2025||
Why not use a series of cargo drones and lift it with ropes? These blades are pretty damn aerodynamic (they are not much different from an airplane wing).
Analemma_ 9/16/2025||
I'm curious why they went with fixed-wing aircraft and not airships for this purpose. Wouldn't an airship work much better for delivering blades to e.g. the top of a mountain ridge? Or is the plan to fly the blades to the nearest flat area and then drive the rest of the way, without having to worry about tunnels and overpasses.
lkbm 9/17/2025|
> Blimps and airships can carry the weight, but they bring a laundry list of complications. They’re too slow, need an expensive hangar to shield them from bad weather, require helium—which is currently scarce—and struggle to land when it’s windy. “And by the way, wind farms tend to be windy,” he says.
jp57 9/16/2025||
Finally the use case for the "airship renaissance" I've been hearing about for the last 25 years.

Seriously, some kind of VTOL craft that could deploy the blades directly to the site seems necessary. Then there's ground transport from some airport out into the hinterlands.

lkbm 9/17/2025||
> Blimps and airships can carry the weight, but they bring a laundry list of complications. They’re too slow, need an expensive hangar to shield them from bad weather, require helium—which is currently scarce—and struggle to land when it’s windy. “And by the way, wind farms tend to be windy,” he says.
s0rce 9/17/2025||
Can you make unmanned hydrogen filled versions?
Terr_ 9/16/2025|||
There's still a problem for generic cargo handling: The moment you start to release the cargo, the now-excessively-buoyant vehicle rises away.
mschuster91 9/16/2025|||
Well, while it's hard to transport a 130 meter long windmill blade on a street... the 60 tons of water you'd need to replace it as ballast weight, that's two semi trucks worth. Easy to get to even the most remote sites, you need heavy machinery (and thus, roads) there anyway to build a foundation capable of supporting a 200m high tower.
SoftTalker 9/16/2025||||
You tie it down before you unload. You probably also need to load ballast on for the return trip.
Terr_ 9/16/2025||
Fully landing the craft and anchoring it flat before un/loading limits how efficiently it can work to move cargo, especially in all the situations where a zeppelin/blimp is compelling because there's a lack of infrastructure.
OkayPhysicist 9/16/2025||
Conceptually, you don't need to fully land the craft. If you lower the payload by cable, those cables are your anchor line. Then you adjust buoyancy until you're no longer straining against the cables, cut anchor, and float away.
quesera 9/16/2025||
Can an airship compensate for 60-75 tonnes of buoyancy change? Releasing helium sounds expensive.
OkayPhysicist 9/16/2025|||
you don't need to vent it if you can compress it. 1 cubic meter of helium replaced with 1 cubic meter of air raises the weight of the craft by ~1.5 kg. That means we need to be able to reduce our helium volume by 50,000 m^3. If (optimistically) we can pressurize the helium to 2 atmospheres, then we only need a 100,000 m^3 envelope. Which is huge, but half the size of the Hindenburg. Realistically, we'd probably get worse compression than that, but it's within an order of magnitude of feasible.
Terr_ 9/17/2025||
> If (optimistically) we can pressurize the helium to 2 atmospheres

It's been a long time since my physics classes, but wouldn't the require 4864 megajoules of energy [0] while raising the temperature of the gas from something like 20C -> 113C?

Spreading that energy-use over 15 minutes, maybe 5 megawatts dedicated to compression.

[0] https://www.omnicalculator.com/physics/thermodynamic-process...

OkayPhysicist 9/22/2025|||
Conceptually, since the airship is tethered to the ground during that compression, the power could be sourced from a ground tether as well. The problem would be the pressure vessel, which is why something like a 200,000 m3 1 atm helium going to 150,000 m3 1.33 atm would be more reasonable.
Terr_ 9/17/2025|||
P.S.: Same tool but this link that pre-fills the input boxes with numbers.

https://www.omnicalculator.com/physics/thermodynamic-process...

SoftTalker 9/16/2025||||
You could load ballast (maybe water) as you unload the cargo.
Terr_ 9/16/2025|||
Looks like the ballpark of $100k per metric ton, definitely not something you want to vent if you can help it.
daemonologist 9/16/2025|||
You can compress the lifting gas (at the cost of energy and equipment weight of course) before unloading to remain ~neutrally bouyant.
cratermoon 9/17/2025||
The Sikorsky S-64 Skycrane comes to mind. The range of ~300km would seem to be a limiting factor.
alright2565 9/16/2025|
The big question is why not build the turbines offshore?

The article briefly mentions this, and that the off-shore blades are over twice the length of the blades this airplane is designed for, but it doesn't look at all at the economics of either option.

bluGill 9/16/2025|
Offshore is not a problem, they build a factory on the coast and put it on a boat.

On shore is a problem - there is a lot of the world where people live that isn't close to a sea. Iowa has more than 6000 despite being hundreds of miles from the nearest sea. (most aren't even close to the Mississippi river)

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