How a Utility-Scale Wind Turbine Is Built

1. Site Selection & Planning For A Wind Turbine

Wind resource assessment: Measure wind speeds over 1–2 years using meteorological masts or LiDAR.
Grid connection study: Ensure transmission lines can handle generated power.
Environmental & social studies: Wildlife impact, noise, visual impact, local regulations.
Land acquisition & permits: Work with local governments and landowners.

2. Design & Engineering

Turbine size: Most modern turbines are 2–6 MW onshore and 8–15 MW offshore.
Blade length: 40–120 meters (longer = more power, but harder to transport).
Tower height: 80–150 meters for onshore; 100–200 meters offshore.
Generator system:
- Direct drive (no gearbox, low maintenance).
- Gearbox drive (lighter generator, more complex).

3. Major Components

Rotor Blades
- Made of fiberglass, carbon fiber, or composite materials.
- Manufactured in huge molds with resin infusion.
Nacelle (the “box” at the top)
- Contains gearbox (if used), generator, cooling, yaw system, and control electronics.
Tower
- Made of steel sections, bolted together on-site.
- Offshore: may use monopiles, jackets, or floating platforms.
Hub
- Connects blades to the main shaft.
Control system
- Monitors wind speed, direction, power output, safety shutdown.

4. Manufacturing Process

Blades: Built in specialized blade factories. Each blade can weigh 10–50 tons.
Towers: Fabricated in steel sections, transported by trucks or ships.
Nacelle & Generator: Assembled in factories with heavy-duty machining.

5. Transportation & Logistics

Blades, nacelles, and tower sections are oversized loads.
Requires special trailers, ships (for offshore), and cranes.
Route planning is critical (roads, bridges, tunnels).

6. Construction & Installation

Foundation
- Onshore: Reinforced concrete base (can be 15–20 m diameter, 2–4 m deep).
- Offshore: Monopiles driven into seabed or floating platforms anchored with mooring lines.
Tower erection
- Steel sections lifted and bolted together with massive cranes.
Nacelle installation
- Lifted and secured on top of the tower.
Blade installation
- Blades attached individually or as a pre-assembled rotor.
Electrical connection
- Cables run down the tower to transformers and the grid.

7. Commissioning

Turbine is tested for safety systems, yaw alignment, and electrical synchronization with the grid.
SCADA (Supervisory Control and Data Acquisition) systems are set up for remote monitoring.

8. Operation & Maintenance

Lifespan: ~20–25 years.
Maintenance: Regular inspection, lubrication, gearbox/generator servicing.
Repowering: After 15–20 years, blades or nacelle may be upgraded with new tech.

⚙️ Key Numbers for Modern Wind Farms

Onshore turbine: 2–5 MW, 80–150 m tower, 100 m rotor diameter.
Offshore turbine: 8–15 MW, 100–200 m tower, 150–240 m rotor diameter.
Cost per turbine: ~$3–5 million (onshore), ~$10–20 million (offshore).
Wind farm: Dozens to hundreds of turbines, connected to a substation.

👉 So in short: you don’t “build” one in a workshop — they’re manufactured in specialized global facilities (Siemens Gamesa, Vestas, GE, Goldwind, etc.) and then installed by engineering, procurement, and construction (EPC) teams with cranes, ships, and heavy equipment.