Client Background

A leading renewable energy manufacturer operating a state-of-the-art wind tower production facility in Iowa faced unprecedented demand as the wind energy sector experienced rapid growth. The facility specialized in manufacturing large-scale wind tower sections for utility wind farms across the Midwest, with each tower section requiring precise fabrication and welding to meet strict industry standards and safety requirements.

The Challenge

The wind tower manufacturer faced critical production challenges that threatened their ability to capitalize on market opportunities:

  • Specialized Skill Requirements: Finding welders with specific structural steel fabrication experience capable of working with thick-plate materials and meeting AWS D1.1 structural welding codes.
  • Aggressive Production Timeline: Meeting contractual delivery deadlines for multiple wind farm projects while scaling production from 8 to 15 tower sections per month.
  • Quality Standards: Maintaining stringent weld quality requirements with 100% visual inspection and ultrasonic testing protocols for critical connections.
  • Workforce Scalability: Rapidly expanding the welding workforce by 50% while maintaining consistent quality and safety standards across all shifts.
  • Regional Talent Shortage: Competing for skilled welders in a tight Iowa labor market where qualified structural fabricators were in high demand.

The Solution

Advastar delivered a comprehensive welding workforce solution tailored to wind tower manufacturing requirements:

  • Targeted Recruitment: Sourced and deployed 15 certified welders with proven heavy fabrication experience in structural steel and plate welding applications.
  • Technical Expertise: Provided welders skilled in GMAW, FCAW, and SAW processes required for thick-plate tower section fabrication and assembly.
  • Production Support: Staffed multiple fabrication cells including tower section welding, precision fit-up operations, and field assembly preparation.
  • Quality Assurance: Supplied welders pre-qualified to AWS D1.1 standards with documented weld test certifications and quality track records.
  • Flexible Scheduling: Structured crews across day and night shifts to maximize production throughput and equipment utilization.

The Outcome

Advastar’s skilled trades staffing solution delivered measurable results for the renewable energy manufacturer:

  • Production Acceleration: Increased tower section output by 30%, enabling the facility to meet growing market demand and capture additional contracts.
  • Schedule Achievement: Met 100% of contractual delivery deadlines across multiple wind farm projects, avoiding costly liquidated damages.
  • Quality Maintenance: Achieved consistent weld quality with pass rates exceeding 95% on first inspection, reducing rework and material costs.
  • Strategic Partnership: Established a long-term staffing partnership with Advastar becoming the exclusive skilled trades provider for ongoing expansion.
  • Market Position: Strengthened the manufacturer’s reputation as a reliable supplier, leading to additional contracts worth $45 million in new business.