The Foundation of Wind Energy: Built with Structural Steel

When most people look at a wind turbine, they’re staring 300 feet in the air at spinning blades.

But the real strength? It begins underground, and structural steel takes center stage.

Swanton Welding is more than a structural steel fabricator. We specialize in providing heavy-duty, precision steel fabrication for the wind energy industry, offering a range of services from base plates to custom structural components.

If the foundation isn’t done right, nothing above it matters.

It All Starts at the Base

Wind turbine foundations are serious business. These massive structures have one job: keep the entire turbine standing — and standing strong — for 20+ years. That means withstanding intense rotational forces from the blades, shifting soil conditions, and constant exposure to the elements.

At the heart of these foundations are two components: base plates and anchor bolt cages.

• Base Plates are the interface between the concrete foundation and the turbine tower. These thick, heavy-duty steel plates need to be absolutely flat, structurally sound, and machined to exact tolerances. If the plate isn’t perfect, you risk improper load transfer or uneven stress on the tower — a small problem at the base can lead to big issues 300 feet up.
• Anchor Bolt Cages act like the buried skeleton of the turbine. These assemblies tie everything together below the surface, securing the tower against tipping, vibration, and extreme winds. A single cage can involve dozens of bolts, precisely positioned and welded into place, often enclosed in rebar and encased in concrete.

Every component in this system has to be fabricated with precision. Holes must line up. Welds must be strong and clean. Dimensions must be exact. Once these components are in the ground, there’s no going back — and there’s no room for error.

That’s why fabrication quality isn’t just important — it’s foundational. And it’s where Swanton Welding excels.

Why Structural Steel?

As a leading structural steel fabricator, we recognize the importance of materials that can withstand extreme stress and environmental conditions. Steel is the material of choice for wind turbine foundations due to its durability, weldability, and long lifespan.

And we’ve got the shop to match: oversized bays, heavy-duty rolling equipment, and skilled fabricators who’ve been in the business for decades.

Built for Wind Projects: Heavy, Precise, and Ready to Move

As an experienced structural steel fabricator, we are equipped with heavy-duty machinery and the know-how to handle the demands of large, complex projects. Our fabrication process is built to deliver the consistency, durability, and precision essential for wind energy components.

Delays in fabrication can disrupt field schedules, incur additional costs, and impact your entire supply chain.

That’s why our team — and our equipment — is built specifically for large, complex, and demanding jobs like these.

• Heavy Plate Rolling Capacity

Swanton Welding is equipped with industry-leading rolling capabilities, including our Parmigiani, the gold standard in metal rolling and forming. With this machine, we can roll thick plates and form precision arcs, cones, and cylinders for components like rolled tanks, flanges, and structural supports. It’s not just about power — it’s about getting the roll right the first time.

• Large-Scale Welding and Fabrication

Our team specializes in oversized and heavy fabrication, working with a wide range of materials including mild steel, stainless steel, and aluminum. We regularly fabricate complex, large-format parts, including frames, hoppers, cones, arcs, rolled tanks, chutes, guards, handrails, cyclones, elbows, and sheet metal assemblies.

• Precision Metal Forming

With years of experience as a trusted structural steel fabricator, we use state-of-the-art equipment to ensure tight tolerances in every part. Our Cincinnati press brake and advanced welding techniques guarantee that all components meet the precise specifications necessary for wind projects. With a 400-ton capacity and the ability to handle materials up to 12 feet long, Swanton can deliver consistent bends and precise angles, eliminating guesswork and ensuring perfect fit on-site. We combine this with advanced welding, machining, and plate rolling to ensure every piece fits seamlessly into your project.

Smooth Field Coordination

At Swanton Welding, we know the job isn’t done just because the parts are fabricated. Field installation is where everything comes together, and the last thing your crew needs is a missing piece, misaligned hole, or a surprise fit issue.

That’s why our team takes coordination seriously. We work closely with your field crews and project managers to make sure that everything arriving on-site is correct, complete, and installation-ready.

One of the biggest ways we support your success? We preassemble your project in-house before it ever leaves our facility. Whether it’s a frame, ducting system, or structural base, we mock it up here first, checking fit, alignment, and weld accuracy. That means when your crew gets it in the field, it fits together just as planned.

We also handle logistics in-house, giving us full control over delivery timelines and minimizing risks. Whether it’s labeled crates, specific rigging instructions, or phased deliveries, your components arrive exactly how and when you need them.

Partnering With OEMs From the Start

As a structural steel fabricator focused on delivering custom solutions, we work closely with OEMs from the start to ensure designs are manufacturable and meet both your timelines and quality standards.

When you bring your designs to us, our experienced project managers become an extension of your team. We will review your specifications closely, making sure they are not only clear but also practical for fabrication. If there’s a more efficient or cost-effective way to achieve the same goal, we’ll talk through it with you.

From there, we work to ensure your design is fully manufacturable within your timeline and budget. Our estimating team knows how to transform a complex set of plans into a realistic production schedule and how to identify and flag any potential bottlenecks before they cause delays.

We don’t just take prints and start cutting — we ask questions, offer suggestions, and make sure your product is built to last and delivered on time.

We Know Wind

Wind energy projects move fast and demand precision. At Swanton Welding, we understand the unique challenges that come with fabricating for the wind industry — and we’re built to meet them head-on.

These projects often involve oversized components, tight schedules, and coordination across multiple teams and vendors. Whether it’s a base plate that needs to meet exacting flatness specs or an anchor bolt cage heading to a remote site, there’s no room for error — and no time for delays.

That’s why we’ve structured our operations for scale, speed, and quality. We operate three strategically located facilities:

• Our main facility in Swanton, Ohio
• A heavy and oversized fabrication center in Pettisville, Ohio
• A full-service facility in Griffin, Georgia

Each is strategically positioned near major highways and rail lines, providing us with fast and reliable access to regional and national shipping routes. But we don’t just rely on third parties — we can also handle transportation and logistics in-house, giving us full control over delivery timelines and freight coordination.

From the moment your project hits our floor, it stays on our radar. We assign a dedicated project manager and, at the customer’s request, our in-house Certified Welding Inspector (CWI) oversees every critical phase. This level of quality assurance ensures your parts meet both your specs and industry standards, every step of the way.

We don’t just build to print, we build to perform, and we follow your project from start to finish to make sure it delivers.

Harness Wind Power With A Strong Foundation From Swanton Welding

Wind turbines are only as strong as their foundations, and those foundations are only as good as the steelwork behind them.

If you’re looking for a structural fabricator that’s experienced, equipped, and ready to support your next renewable energy project, we’d love to talk. Contact us for a quote today.