POWER SYSTEMSWINDIDI- 0253rev.10

IDI-0253 Positions for its transportation and installation ECO74, ECO80 1.6, ECO 86 and ECO80 2.0 Wind TurbinesAuthor: M Tarrago Revised by: M Tarrago Approved by: JR GD

REVISIONSRev. 10 Date 25/01/2010 Description of changes Platforms, Roads, Eco86, Eco80 2.0 with 80m tower added. Pages amended All Author M Tarrago

1. Contents1. 2. 3. 4. 5. 6. Contents .................................................................................................................... 1 Purpose ..................................................................................................................... 2 Scope ........................................................................................................................ 2 Definitions ................................................................................................................. 2 Responsibilities ........................................................................................................... 2 Generated / Reference Document .................................................................................. 2 6.1 Reference document ............................................................................................ 2 6.2 Generated document............................................................................................ 3 7. Equipment, tooling and tools required............................................................................. 3 8. Procedures................................................................................................................ 3 8.1 Sizes and weights................................................................................................ 3 8.1.1 Towers ........................................................................................................ 3 8.1.2 Nacelles....................................................................................................... 3 8.1.3 Generator .................................................................................................... 3 8.1.4 Extenders (for each blade) Block 4 ................................................................... 3 8.1.5 Blades ......................................................................................................... 4 8.2 Transportation equipment .................................................................................... 5 8.2.1 Tower transportation equipment...................................................................... 5 8.2.2 Nacelle transportation equipment .................................................................... 5 8.2.3 Transportation equipment for small material...................................................... 5 8.2.4 Blade transportation equipment....................................................................... 5 8.3 Minimum crane requirements for nacelle ............................................................... 5 8.4 Requirements for accesses and roadways............................................................... 6 8.5 Radii on bends for ECO74 wind turbines................................................................. 7 8.6 Turn radii for ECO80, ECO86 and ECO80 2.0 wind turbines ....................................... 7 8.7 Civil works requirements for the 56-60-70 m tower................................................. 8 8.7.1 Internal wind farm equipment ......................................................................... 8 8.7.2 Assembly platforms ....................................................................................... 8 8.8 Civil works requirements for the 80 m tower ........................................................ 10 8.8.1 Internal routes ............................................................................................ 10 8.8.2 Assembly platforms ..................................................................................... 11 8.9 Requirements for the storage area ...................................................................... 13 8.9.1 Storage field required for wind turbine components .......................................... 13 8.9.2 Field required per wind turbine ...................................................................... 14

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9.

Occupational Health and Safety. Environment.......................................................... 14 9.1 Occupational risk assessment ............................................................................. 15 10. Appendices............................................................................................................... 17 10.1 Distribution guide for cranes and components on the platform for 60 m tower ......... 17 10.2 Distribution guide for cranes and components on the platform for 70m tower .......... 18 10.3 Distribution guide for cranes and components on the platform for 80m tower .......... 19 10.4 Platform for assembly of the main crane lattice boom for the 80 m tower. ............... 20 10.5 Trucks, illustrative diagrams............................................................................... 21

2. PurposeThese instructions establish the general positions for transportation, handling and installation of the ECO74, ECO80-86 1.6 and ECO80 2.0 wind turbines.

3. ScopeThis IDI is valid for ECO-74/80/80 C-II/86 and ECO-80 2.0 series wind turbines.

4. DefinitionsNot applicable.

5. ResponsibilitiesThe following hypotheses have been considered in these instructions: Existence of appropriate general access roads. Appropriate road surface conditions. No height and weight limitations for the required transportation. No obstacles imposed by the different authorities to obtain standard transportation and vehicle traffic permits. The requirements described in this document are illustrative and may by modified by ALSTOM WIND without prior notice. Consult ALSTOM WIND for any site that does not meet with these conditions. Before the start of installation, ALSTOM WIND will check that the construction work meets the requirements described herein.

6. Generated / Reference Document6.1 Reference documentAll of the diagrams of the components for the ECO-74/80/80 C-II/86 and ECO-80 2.0 wind turbine series.

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6.2

Generated document

FRM- 0314

7. Equipment, tooling and tools requiredThose described in the following IDI. Transport equipment described in FRM.0500 according to the wind turbine version.

8. Procedures8.1 8.1.1 Sizes and weights Towers

Note: These weights are for reference only and include the internal parts of the tower. 8.1.2 Nacelles

The transport support is used in all cases. Description ECO74 and ECO80-86 1.6 with generator Length 13.1 m Width 3.40 m 3.40 m 3.40 m 3.40 m High 3.80 m 3.80 m 3.80 m 3.80 m Weight 67.00 T 59.30 T 70.00 T 62.50 T Diagram 01812011 01812011 12000031 12000031

ECO74 and ECO80-86 1.6 without genera13.1 m tor ECO80 2.0, with generator ECO80 2.0, without generator 13.1 m 13.1 m

8.1.3

GeneratorLength Width High Weight Diagram

Description

ECO74, ECO80-86 1.6 and ECO80 2.0

3.47 m

1.95 m

2.00 m

7.70 T

01812022-1

8.1.4

Extenders (for each blade) Block 4Length Width High Weight Diagram

Description

ECO74 ECO80-86 1.6 and ECO80 2.0

2.24 m 1.98 m

2.14m 2.14m

2.30m 2.30m

5.53 T 5.19 T

01807411 01807413

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8.1.5

BladesLength Width High Weight Diagram

Description

ECO74 : Unit ECO74 : 2 Units ECO80 1.6 and ECO80 2.0: Unit ECO86 1.6: Unit

34.00 m 34.30 m 37.68 m 40.3 m

2.36 m 3.00 m 2.33 m 2.43 m

2.62 m 2.75 m 2.62 m 2.79 m

5.65 T 12.00 T 6.2 T 8T

01812007 01807441 01812019 07800166

Rotor height Total weight Lower section Weight Maximum diameter Minimum diameter High Diagram Section 1 Weight Height with door Maximum diameter Minimum diameter Length Diagram Section 2 Weight Maximum diameter Minimum diameter Length Diagram Section 3 Weight Maximum diameter Minimum diameter Length Diagram

ECO74- 80- 86 1.6 56 m 60 m 116.44 T 99.73 T 7.73 T 3.97 m 3.68 m 7.73 T 3.97 m 3.68 m

70 m 132.98 T 8.43 T 4.25 m 3.95 m

80 m 171.26 T 11.26 T 4.58 m 4.27 m

ECO80 2.0 70 m 80 m 145.00 T 171.26 T 11.000 T 4.25 m 3.95 m 11,312 T 4.58 m 4.27 m

2.40 m 2.40 m 2.40 m 2.41 m 01812018 01812018 01812006 01812030 23.00 T 3.76 m 3.68 m 3.41 m 23.00 T 3.76 m 3.68 m 3.41 m 53.25 T 4.38 m 3.95 m 3.41 m 61.50 T 4.36 m 4.27 m 4.26 m

2.40 m 2.40 m 12000002 12000036 63.00 T 4.38 m 3.95 m 3.41 m 61.50 T 4.36 m 4.27 m 4.26 m

10.00 m 10.00 m 20.10 m 19.50m 01812026 01812014 01812002 01812029 37.00 T 3.40 m 2.90 m 37.50 T 3.41 m 2.90 m 37.50 T 3.41 m 2.90 m 58.50 T 4.26 m 3.22 m

20.10 m 19.50m 12000001 12000037 42.00 T 3.41 m 2.90 m 58.50 T 4.26 m 3.22 m

20.00 m 20.00 m 20.00 m 28.25 m 01812026 01812014 01812002 01812029 48.71 T 2.90 m 2.13 m 33.8 T 2.90 m 2.13 m 33.80 T 2.90 m 2.13 m 40.00 T 3.22 m 2.13 m

20.00 m 28.25 m 12000001 12000037 37.00 T 2.90 m 2.13 m 40.00 T 3.22 m 2.13 m

24.00 m 28.00 m 28.00 m 30.00 m 01812026 01812014 01812002 01812029

28.00 m 30.00 m 12000001 12000037

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8.2 8.2.1

Transportation equipment Tower transportation equipmentU/Trans. Transportation equipment description (options)

Component

Lower section Section 1

3 1

Flat deck Extending pipe loader with self-steering wheels on rear axles Clamp and dolly Double clamp Extending platform with self-steering wheels on rear axles Extending pipe loader with self-steering wheels on rear axles Clamp and dolly. Extending platform with self-steering wheels on rear axle.

Section 2 Section 3

1 1

8.2.2

Nacelle transportation equipment Quantity 1 Transportation equipment description Lowered pipe loader with self-steering wheels on rear axles.

Component Nacelle

8.2.3

Transportation equipment for small material Quantity 1 Transportation equipment description Conventional deck

Component Extenders, generator

8.2.4

Blade transportation equipment Quantity 1 Transportation equipment description Extending platform with self-steering wheels on rear axles.

Component Blades

8.3

Minimum crane requirements for nacelle 56 m 500 t Liebherr LTM 1500 70 m 120 t Demag AC-395 120 t Demag AC-395 65 m 60 m 500 t Liebherr LTM 1500 70 m 180 t Demag AC-180 75 m 70 m 500 t Demag AC-700 Liebherr LTM 1500 80 m 80 m 550 t Demag CC 2500 Liebherr LG 1550 90 m 225 t Liebherr LTM 225 85 m

Rotor height Main crane Model and guide reference Minimum height under hook Auxiliary crane Model and guide reference

Minimum height under hook 60 m

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8.4

Requirements for accesses and roadways

The access roads to the sites must withstand the same loads and meet the same requirements as the tracks inside the wind farm itself. The access roads must allow for the base of each wind turbine to reach the site with all its components at any time of year. Depending on the wind farm distribution of the turbines for each site, whether it has one or several entrances, at least the following will pass along the tracks inside the wind farm per wind turbine: 3 Cranes per wind turbine, maximum weight 130 tons with a maximum of 15 tons per axle. 12 units of special transportation per wind turbine, with a maximum of 14 tons per axle. A specific study must be carried out to determine the type of route restructuring required, the results of which may determine the general instructions given below: At least the existing layer of soil (scrub clearing) will be removed. The resulting levelled ground must be of suitable characteristics for the traffic it is to withstand (equivalent of E2 in Spain). If necessary, it will be improved by providing selected or appropriate material, where possible and under no circumstances of a quality below tolerable levels, with particular attention given to the plasticity of the material. To improve the levelled ground and construction of embankments, special attention will be paid not only to the quality of the material but to the implementation process commonly sanctioned by the following practice: Compacting in layers with a maximum thickness of 30 cm to 95% MP, with the provision of water (irrigation). The wearing course (surface) will be made with artificial gravel or equivalent, with materials of reduced plasticity (IP 5) being accepted. The remaining geotechnical characteristics corresponding to artificial gravel will be maintained. The thickness of the wearing course will depend on the quality of the levelled area, although will be no lower than 25 cm, compacted to 98% MP. Correct crossways and lengthways drainage must be ensured. In the event of pot-holes, as a general rule, a layer of at least 50 cm. of coarse aggregate will be used for restructuring to avoid water retention. In sections of the wind farm where the road surface is made of clay, or, in general, where there is a bad response to water and where it is of such a depth that complete restructuring is not possible, a double layer of geotextile will be used to separate the natural ground from the levelled area to avoid contaminating the fill material and to increase the supporting capacity of the levelled area. The kerbs must be covered where required by the geotechnical study and, in all circumstances, must be of a sufficient capacity and remain free of plant life and obstacles that could retain water. Any brickwork must be of a sufficient section. For easier vehicle traffic, kerbs will occasionally be filled and compacted (a typical example: interior bends). This temporary work must be removed once the foreseen traffic has ended. Recommended slope on cut 1/2 and on fill 3/2, in line with the geotechnical conditions of the site.

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The tracks must be built with a minimum banking necessary for water evacuation (crossways drainage). The direction of the banking will depend on the position of the kerbs and the final gradient of the road. Special attention will be paid to vertical alignments on gradient changes (concave and convex) due to the length of most of the components to be transported. In general, the vertical parameter (Kv) must be higher than 250. Note that the parameters indicated in the following table (excess width, obstacles on the inside and outside of the bends, etc.) for the radii of the bends consider the most critical components to be the blades, due to their length, and sections 1 and 2, due to their combined weight and length.

8.5Width (A)

Radii on bends for ECO74 wind turbinesMinimum radius Excess width (S, (R) Ri) Condition of the bend

5m 5m 5m 5m

50 m 43m 33 m 28 m

3m 4m

With obstacles on the inside and outside of the bends. With no obstacles on the inside and outside of the bends. With access width With access width

8.6Width (A)

Turn radii for ECO80, ECO86 and ECO80 2.0 wind turbinesMinimum radius Excess width (S, (R) Ri) Condition of the bend

5m 5m 5m 5m

55 m 45 m 37 m 33 m

3m 5m

With obstacles on the inside and outside of the bends. With no obstacles on the inside and outside of the bends. With access width With access width

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8.7 8.7.1

Civil works requirements for the 56-60-70 m tower Internal wind farm equipment

For wind turbines with a hub height of up to 70 m., the road must be 5 m wide in line with the following diagram:

SERVICE ROAD AXIS

ARTIFICIAL GRAVEL

COMPACT FILL

PRIOR LEVELLING

Detailed view of the profile of the on-site track for 5 metre-wide roads. The width of the road surface will be 5 m on straight sections. The excess widths indicated in Point 7.1 and 7.2, will be implemented on bends and, therefore, must be planned with a sufficient excavated width to cover banks, kerbs and other roadway elements as well as the aforementioned width. 8.7.1.1 Track gradients The acceptable gradient with gravel paving is up to 12%. The provisions indicated in the previous section apply to sections with these characteristics. The absolute maximum gradient of the tracks is 15%. For sections with a gradient of between 12 and 15%, the provisions in the above section apply, except for the road surface that will be made of concrete with HA-20, a minimum thickness of 20 cm. and steel mesh, expansion joints every 10 metres and a rough surface finish. On all accounts, for gradients between 12 and 15%, the need for towing transport must be assessed and its cost evaluated. 8.7.2 Assembly platforms

The assembly platform is where the cranes are located for hoisting manoeuvres of the wind turbine, it is also used for temporarily storing the different components; where the crane is located, the platform must be solid enough to support all of the forces transmitted by the crane to the ground during the hoisting process of different compartments. The process used for the construction of platforms is the same as that used for the construction of roads and defined in Point 8.7 and is the same as for the platforms used for the construction of the 80 m tower Point 8.8.2 (drainage, flattening, filling, compacting, etc.) The material used must be similar to that used on the routes.

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The maximum gradient allowed in the work area for mobile cranes on wheels is 2% both lengthwise and widthwise. The platform in the area must be able to support the pressure transmitted by the cranes to the ground through the load distribution beams. The minimum pressure transmitted by the crane on wheels (TC) is 50 T/m Access to the platform from the track for cranes, lorries and vehicles must be easy and there must be no differences in level between the roadway and the platform. If the cable ditch passes between the platform and the route, the cables must be covered by pipes and concrete. The finish must be the same for the platform and the route. 8.7.2.1 Platform sizes The platform sizes are shown in the table below and are valid for 56 and 70 m towers The base of the wind turbine may not be more than 0.5 m above the assembly platform level in any case. The area where the main crane is stabilised is within the radius of gyration. The turn radius in the table below is indicated as RG, this area must be particularly compacted. In the plan included (01812048) a possible location for the crane on the platform is shown. The area close to the wind turbine (area shown in the following illustration) located between the crane location and the base of the tower, must be at the same level as the platform and compacted. All wind turbines must have a temporary storage area around the platform and this storage area must be flat, at the same level and compacted so that it may support 50 T/m If the storage area cannot be constructed next to the platform then a storage field must be constructed in the wind farm. The dimensions of this storage field are given in Point 10 of this document. The base of the tower must be centred on the longitudinal axis of the platform [E].

Rotor height Crane radius of gyration (RG) A= B= C= D= E= F=

56 m 20 m 24m 22 m6m

60 m 20 m 24 m 22 m6m

70 m 22 m 28 m 23 m 6m 5m 11.5 m 6m

5m 11 m 6m

5m 11 m 6m

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WIND TURBINE ENTRANCE ROAD TRAC

CRANE SITE AREA

8.8 8.8.1

Civil works requirements for the 80 m tower Internal routes

A crane with lattice boom installed on chain chassis (CC) or lorry chassis (TC) must be used to install ECOTCNIA wind turbines with an 80-metre tower. In the case of a TC crane, the boom must be completely removed when moving it from one wind turbine to another. The tracks must be 5 metres wide. A CC crane is recommended for installation of 80 m towers, adapting the tracks inside the site for movement of the chain crane mounted inside the wind farm among wind turbines. In order to move the crane, the following are required: Option 1: a compacted track (as defined in Point 7) 10.5 metres in width on its straight sections. All 90 bends must be 13 metres in width. These dimensions are only valid during installation.

Service road axis

Option 2: the 5 metre-wide track in the wind farm is available to move the crane. A temporary 2-metre track is added and duly compacted and levelled. The crane passes a chain along the permanent 5-metre track and the 2nd chain along the track adapted for the crane to move. After the crane has passed, the temporary track is removed. The necessary civil engineering equipment is required on site for this option throughout the installation.

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Crane running axis

Temporary track is removed after installation

For both options, the gradient of the track between wind turbines can be 6% maximum and 1% laterally, and the area of movement of the crane chains must be compacted to support a minimum of 50 T/m To move the complete crane, the sideways and lengthways gradient conditions mentioned in the point above must be met. Where these conditions are not met, the crane must be totally or partially dismantled with the subsequent cost of the operation. Where the crane is dismantled, the necessary gradients are the same as for the relevant instructions for the 70 m tower in the Point 8.1.1. The requirements above must absolutely be fulfilled in order to move the main crane between wind turbines in the same location. If the fully assembled crane cannot be moved between wind turbines then auxiliary cranes, transport equipment and personnel etc will be required for the manoeuvres. All of the required equipment is costly and must be evaluated for each wind farm.

8.8.2

Assembly platforms

The assembly platform is where the cranes are located for hoisting manoeuvres of the wind turbine, it is also used for temporarily storing the different components; where the crane is located, the platform must be solid enough to support all of the forces transmitted by the crane to the ground during the hoisting process of different compartments. The material used must be similar to that used on the routes. The maximum slope permissible in the work area is 1% longitudinal and 0.5% transversal. The platform in the area must be able to support the pressure transmitted by the cranes to the ground through the load distribution beams, the minimum pressure transmitted by the chain crane (CC) is 53 T/m The minimum work area for the main crane, for 80 m towers is defined in the table of Point 9.2.1., the radius of the crane varies between 18 and 24 m.

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The platform finish must consist of 10 cm of artificial concrete pavement compacted to 98% of MP, similar to the route. This depends on the width of the routes for each location. When moving the chain crane for assembly between wind turbines, if a route of 10.5 m wide is not available then, in order to fit the lattice boom of the main crane, the following are required: A cleared, levelled area measuring 102 metres in length x 4 in width alongside the 5-metre road connecting the different wind turbines. This area begins at the wind turbine platform. In some cases the route itself may be used. This cleared area must be parallel to the road linking the different wind turbines and must have two areas for placing the auxiliary crane. The platforms for locating the auxiliary cranes that mount the lattice boom on the main crane must be 12x10 metres. These areas must be close to the tracks connecting several wind turbines in the wind farm and between 50 and 70 metres from the centre of the wind turbine installation platform.

8.8.2.1 Crane platform dimensions The platform size is given in the table below. The base of the wind turbine may not be more than 0.5 m above the assembly platform level in any case. The location for the main crane is within the radius of gyration, in the table below the radius of gyration is indicated as RG, this area must be especially compacted. The platform distribution plans attached provide a guide as to the location of the crane. The platform must be accessible from the route for cranes, trucks and vehicles and there must be no inclinations between the road and the platform. If the cable ditch passes between the platform and the road than tubes and concrete must be used and the finish must be the same as that for the platform and the road. The area close to the wind turbine (stripped area shown in the following illustration) located between the crane location and the base of the tower, must be at the same level as the platform and reasonably compacted. All wind turbines must have a temporary storage area around the platform and this storage area must be flat, at the same level and compacted to the same degree as the platform. If the storage area cannot be constructed next to the platform then a storage field must be constructed in the wind farm. The dimensions of this storage field are given in Point 10 of this document. The base of the tower must be centred on the longitudinal axis of the platform [E].

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Crane radius of gyration (RG) 24 m

A 35m

Rotor height 80 m B C 23 m 6m

D 5m

E 11.5 m

F 7m

WIND TURBINE ENTRANCE ROAD TRACK

CRANE SITE AREA

ALL OF THE COMPACT AREA THE SAME AS THE ROAD

8.9

Requirements for the storage area

If the storage area cannot be constructed next to the platform then a storage area must be provided in the wind farm. The storage area is only required during the installation process. The preparation of the storage area is the same as that for the wind turbine assembly platform. Depending on the wind farm, the storage area can be used for all components or for separate components such as blades, blades + section 3, etc. If one or several storage areas are to be provided in a different location to the assembly platform for each wind turbine, the proposal must be sent to Alstom. Once the storage field design has been reviewed, Alstom will provide its approval and/or comments and the impact of the storage field(s) on wind turbine assembly logistics. 8.9.1 Storage field required for wind turbine components 56 m 12x4m. 22x4m. 26x3m. 12x4m. 9x9m. 9x39m. 60 m 12x4m. 22x4m. 30x3m. 12x4m. 9x9m. 9x39m. 70 m 22x4m. 22x4m. 30x3m. 12x4m. 9x9m. 9x39m. 80 m 23x4.8m. 25x4m. 25x3.5m. 12x4m. 9x9m. 9x39m.

Rotor height Tower section 1 Tower section 2 Tower section 3Nacelle Extenders Blades for ECO-74, ECO-80

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8.9.2

Field required per wind turbine 56 m 20x39m. 60 m 20x39m. 70 m 20x39m. 80 m 20x50m.

Rotor height Storage area

9. Occupational Health and Safety. EnvironmentPersonnel: Work equipment: Obligatory Preventive Resource present in the work of the contracted company and/or Alstom WIND Those listed in Chapter 7

PPE:

Safety footwear Protective glasses Mechanical protection gloves Safety helmet Work clothing Equipment for working at height (Harness, Y-shaped rope,fall arrest device, carabiners)

Protective face shield Respiratory protection Protective apron for welding work Hearing protection Highly visible reflective jacket. (Smartline or any approved evacuation system that guarantees evacuation according to the height of the wind turbine)

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ATTENTION: - Confirm that none of the elements to be handled exceed 25 kg in weight, otherwise ask a for assistance and/or use mechanical components for lifting loads. - Clear up all the waste and/or leftovers generated in the operation. Store in the location indicated. ATTENTION: Make sure that the components to be handled do not weigh more than 25 kg, ask a colleague for assistance and/or use mechanical elements for lifting loads. NOTE: Operators should read and be familiar with the Safety Data Sheets for the chemical products to be used, prior to be used. 9.1 Occupational risk assessment

An assessment is made of each risk detected using two variables: the probability of the event occurring and the severity of the damage. The following table shows the risk assessment according to these two variables:

SEVERITY Slightly Harmful PROBABILITY Low Medium High Very low Low Medium Harmful Low Medium High Extremely harmful Medium High Very High

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Risk description

Probability

Severity Extremely harmful Harmful

Assessment Medium

Corrective measures Locate and repair weak points on the roadway, prior to the movement of cranes and lorries Observe speed limits established in the work zone Observe the highway code.

Trapping by overturned vehicle Crushing, impact or collision with or against vehicle Accidents when in transit

Low Low

Low

Low

Extremely Harmful

Medium

Blows from objects or toolsTreading on objects

LowMedium

HarmfulSlightly Harmful Extremely harmful

Low

Low

Falling loose objects

High

High

Exposure to extreme temperatures (cold)

Medium

Slightly Harmful

Low

Exposure to extreme temperatures (heat)

Medium

Slightly Harmful Slightly Harmful

Low Low

Falling loose objects

Medium

In adverse weather conditions, extreme caution should be taken during the journey. Use the appropriate tools for each task, as indicated in this report Mechanical protection gloves must be worn Look where you are walking. Before starting out, check that the load is securely fastened and there are no loose components which may fall during the journey. Use of suitable work clothes to protect against cold Drink hot beverages during rest periods. Compliance with INS-0180 Ventilation (wherever possible) of the work area Personnel must keep well-hydrated. Compliance with INS-0180 Before starting out, check that the load is securely fastened.

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10. Appendices10.1 Distribution guide for cranes and components on the platform for 60 m tower

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10.2 Distribution guide for cranes and components on the platform for 70m tower

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10.3 Distribution guide for cranes and components on the platform for 80m tower

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10.4 Platform for assembly of the main crane lattice boom for the 80 m tower.

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10.5 Trucks, illustrative diagrams

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