SEARSPORT, ME — Sprague Energy is leading a large-scale project to unload and transport massive wind turbine components from vessels and rail off the coast of Searsport, Maine. The company is using a fleet of five Manitowoc crawler cranes to efficiently move components from sea vessels to holding yards and then onto trucks that will take them to various wind energy farms across the state.
The operation, which began in January 2024, employs three Manitowoc MLC150s, one MLC250, and one MLC300 VPC-MAX, all of which perform up to 30 lifts per day. Loads vary from 24.2 tons to 101.4 tons, and the work is expected to conclude in October 2024.
Maine is set to significantly expand its current onshore wind capacity in the upcoming years. Together, the new wind energy projects will power over 62,000 homes and reduce CO2 emissions equivalent to 50,000 cars annually. Already, 26.19 percent of the state’s installed energy generation capacity comes from wind.
As the energy industry goes through significant changes, Manitowoc and its customers are playing a role in enabling this transition with efficient and innovative tools.
Sprague Energy, Shawmut Equipment, and a partnering transportation company are working on the Searsport project together. The process of unloading and moving the parts demands coordination and precision. Some larger components, like turbine blades, can reach lengths of up to 250 feet and require two cranes working in tandem to lift them.
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“Our Manitowoc cranes work together to lift the windmill’s tower sections, blades, hubs, drives, and nacelles,” said Cameron Giroux, Terminal Supervisor at Sprague Energy. “Due to the significant distance between pick points on the turbine blades, we are fortunate to be able to execute two-crane lifts. We rig the components with slings, shackles, and hooks, and use a block and tackle at one end to maintain even pressure and prevent twisting of the blades. After that, we use the cranes to stage loads for the next phase.”
The complexity of the work underlines the importance of the precision and control Manitowoc’s Crane Control System (CCS) offers crane operators.
“Manitowoc’s CCS system is designed to improve operator efficiency and accuracy by offering intuitive controls and advanced diagnostics,” said Brennan Seeliger, Manitowoc’s Product Manager for Crawler Cranes. “Its user-friendly interface enables efficient operation, reducing the learning curve for operators. Users can harness the precise load monitoring, customizable configurations, and automated functions of CCS that enhance job site productivity and reduce the risk of errors. This makes it an invaluable tool for experienced and new crane operators alike.”
Giroux also emphasized how collaboration between Sprague Energy and local Manitowoc dealer Shawmut Equipment has been vital to the project’s success.
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“Together, we assessed each component’s specifications — weights, lengths, styles — and matched them with the appropriate cranes," he said. "Using the load charts as our baseline, we executed a highly coordinated operations plan that’s proving to be quite successful.”
“We’re managing a continuous flow of components from ship, barge, and rail. The logistics are complex, and these cranes are essential for a seamless workflow,” Giroux added. “Without dependable cranes, we’d face significant delays. Fortunately, the Manitowoc cranes have proven reliable, and their performance makes the Manitowoc series ... our preferred choice when wind turbine components are larger.”
