Overhead Cranes for Solar Power Plant Construction & Maintenance
Summary: Kelude Heavy Industry provides crane configuration solutions for solar power plants, covering four key construction phases: module installation, support structure erection, transformer placement, and substation construction. Solutions are tailored for truck cranes with a lifting capacity of 5–80t and fixed cranes with a capacity of 2–10t. The typical investment in lifting equipment per site ranges from approximately $15,000 to $445,000 (including rental). Module installation utilizes truck-mounted cranes or forklift trucks (individual modules weigh 20–35kg), support structures are erected using 25t truck cranes, transformers (8–15t) and main transformers (15–80t) are positioned using truck cranes combined with hydraulic sliding, and substations are equipped with 5–10t single-girder electric cranes for equipment maintenance. This comprehensive approach addresses all hoisting requirements for both large-scale ground-mounted and distributed solar projects.
Crane Configuration for Solar Power Plants
Module Installation | Support Structures | Transformer Placement | Substations
Solar power plant construction involves the installation and handling of numerous photovoltaic (PV) modules, steel support structures, pad-mounted transformers, and substation equipment. Unlike thermal or wind power projects, solar sites predominantly require mid-to-small capacity lifting equipment. However, these operations face unique challenges, including difficult terrain (mountainous, desert, or over-water sites), high-volume repetitive tasks, and the need to prevent module damage. Kelude Heavy Industry offers a comprehensive lifting configuration solution covering every stage, from module installation to substation hoisting.
Scenario 1: Module Installation
• Individual modules weigh 20–35kg; handled with forklifts or manual assistance
• Vacuum lifters or specialized fixtures prevent breakage
• Soft lifting slings provide additional protection
• Facilitates tilted installation and angle adjustment
• Designed for high-volume, efficient operations
• Kelude supplies PV-specific vacuum suction lifters
Lightweight & Breakage Prevention | Vacuum Lifter | High-Volume Efficiency
Scenario 2: Support Structure Erection
• Lifting capacity 25t–50t using truck cranes or crawler cranes
• Handles long components like H-Beams and guide rails
• Adaptable to mountainous or sloped terrain
• Enables rapid relocation and multi-point operations
• Full slewing capability for confined spaces
• Kelude provides specialized spreaders for long PV support components
Long-Component Hoisting | Terrain Adaptability | Rapid Relocation
Scenario 3: Transformer Placement
• Lifting capacity 10t–30t using truck cranes or truck-mounted cranes
• Transformer weight ranges from 5t to 15t
• Suitable for precision equipment; prevents tilting
• Offers rainproof, moisture-proof, and sealed protection
• Ensures accurate positioning and bolt-hole alignment on foundations
• Kelude provides specialized spreaders for transformer placement
Precision Equipment | Tilt Prevention | Accurate Alignment
Scenario 4: Substation Construction
• Lifting capacity 30t–80t using QD cranes, MG cranes, or truck cranes
• Main transformer weight ranges from 20t to 50t
• Indoor overhead type / outdoor gantry
• Dustproof / clean installation environment
• Heavy transport / positioning
• Kelude provides the main transformer hoisting plan
Heavy-Duty Hoisting | Indoor & Outdoor | Main Transformer Plan
Selection Parameters: Four-Zone Comparison
| Parameter Item | Componentinstallation | Support Bracketinstallation | Containerized Substationinstallation | Step-up Substation |
|---|---|---|---|---|
| recommended model | Forklift truck/Truck-mounted crane | truck crane/crawler crane | truck crane/Truck-mounted crane | QD/MG/truck crane |
| Lifting Capacity Scope | 3t~5tForklift truck | 25t~50t | 10t~30t | 30t~80t |
| Lifting spreader Type | Vacuum Lifter/Flexible Lifting Sling | Long Goods Lifting Beam | Dedicated Containerized Substation Lifting spreader | Main Transformer Lifting spreader/lifting lug |
| Working Environment | Ground Level/inclination/tilt Ground Level | Mountainous Terrain/Sloped Terrain | Foundationplatform | Indoor/Outdoor |
| Operational Characteristics | High-Volume Repetitive | Long Goods/Site Relocation | Precision Hole Alignment | Heavy Component Positioning |
| Kruud Solution | Photovoltaic Suction cup Lifting spreader | Long Goods Lifting Beam | Containerized Substationspecialized spreader | Main Transformer Lifting Plan |
Lightweight, High-Efficiency Lifting for PV Module Installation
PV modules weigh 20–35 kg each and feature tempered glass surfaces that are highly prone to cracking during handling and installation. Traditional manual methods are slow and result in high damage rates. Kelude's recommended vacuum suction lifter for PV modules uses a multi-suction-cup evenly distributed design, generating suction pressure of −0.6 to −0.8 bar via a vacuum pump. It can lift 2–4 modules at a time, boosting efficiency by 3–5 times and cutting damage rates to below 0.5%. For floating solar plants, pontoon transport vessels or specialized marine lifting equipment are also required to transfer modules across water.
Mid-Tonnage Lifting for Racking and Substation Installation
PV racking systems are built from hot-dip galvanized H-beams and guide rails, with individual sections ranging from 6 m to 12 m in length. These require 25–50 t truck cranes fitted with long lifting beams for hoisting and positioning. Sloped-terrain projects demand enhanced mobility — Kelude recommends wide-track crawler cranes or all-terrain truck cranes for better adaptability on uneven ground. Pad-mounted transformers weigh 5–15 t and must be set onto concrete foundations. This calls for 10–30 t truck cranes with specialized spreader beams featuring a self-locking anti-tilt mechanism to keep the transformer level throughout lifting and placement.
Heavy Lifting at Substations and Integrated Planning Across the PV Plant
The most critical lifting tasks at the substation involve the main transformer (20–50 t), GIS equipment, and switchgear cabinets. Indoor equipment is handled by QD type overhead cranes, while outdoor transformer installation uses truck cranes or MG type gantry cranes. Kelude can develop a plant-wide lifting equipment coordination plan for PV projects — unifying crane deployment from module installation through to main transformer placement at the substation. This reduces equipment idle time and lowers overall crane rental costs by approximately 15–20%.
Kelude: Crane Service Advantages for Solar Power Plants
Kelude Heavy Industry has years of specialized experience in crane solutions for solar plant construction and maintenance. We provide full-lifecycle lifting solutions — from construction hoisting to O&M servicing — for large ground-mounted plants, hillside installations, fishery-solar hybrid projects, and rooftop distributed PV systems. To date, we have supplied lifting equipment and services to more than 100 solar power plant projects.
FAQ
Q: What lifting equipment is best suited for solar panel installation?
A: For solar panel installation, we recommend a vacuum suction lifter paired with a forklift or pickup truck for transport. Kelude's vacuum lifters can handle 2–4 panels per cycle, boosting installation efficiency by 3–5 times compared to manual labor. For rooftop distributed PV systems, a lightweight basket or roof-mounted hoist is required to move panels to the roof.
Q: What special requirements apply to lifting equipment for mountainous PV sites?
A: Mountainous terrain often features slopes of 10°–30°, making it difficult for standard truck cranes to set up. Kelude recommends wide-track crawler cranes or all-terrain cranes for such projects—the former offers low ground bearing pressure for soft ground, while the latter provides multi-axle steering and automatic leveling. For transporting racking materials, we suggest using trucks with extended cargo beds.
Q: What should be considered when hoisting a pad-mounted transformer?
A: Pad-mounted transformers are precision electrical equipment and must be kept perfectly level during hoisting. Kelude's specialized spreader for these units features independently adjustable lifting chains at all four corners, along with spirit level sensors that trigger an automatic alarm if any corner deviates by more than 3°. All lifting lugs on the transformer top must be engaged and loaded evenly—single-point or diagonal lifting is strictly prohibited.
Q: What lifting capacity is required for main transformer hoisting at a PV substation?
A: The main transformer weight depends on the plant's capacity—a 10MWp PV plant typically has a main transformer of 15t–20t, a 50MWp plant uses 30t–40t, and a 100MWp plant requires 50t–80t. Kelude selects the crane model based on transformer weight plus a 10% safety margin, while also considering transport route width and the bearing capacity of the foundation at the hoisting location.
