In a significant stride for Spain’s offshore wind industry, the first 14 XXL monopiles fabricated by Navantia Seanergies-Windar Renovables have been readied for transport to the Moray West offshore wind farm in Scotland. This milestone, facilitated by Mammoet’s expert handling and transport solutions, underscores the critical role of flexible site planning and specialized equipment in managing such colossal structures.
The increasing size of offshore wind turbines demands innovative engineering to manage the handling of their heavy foundations. These components, often exceeding 90 meters in length and weighing up to 2,000 tons, present unique challenges, particularly in constrained environments like busy docks. The need for precise planning and upgraded equipment becomes paramount.
Navantia Seanergies-Windar Renovables, a pioneering Spanish company in monopile fabrication, collaborated with Mammoet to manage the logistics at their Fene production facility in Ferrol. The task involved transporting these massive monopile foundations through various workstations before loading them onto vessels bound for Scotland.
Mammoet’s strategy was rooted in meticulous preparation and in-depth knowledge of the facility. The monopiles, each 90 meters long and 10 meters in diameter, were moved to a storage area post-manufacture. Knowing the exact weight and center of gravity of each monopile was essential for safe lifting onto installation vessels. Thus, a final weigh-in was conducted for each unit using hydraulic jacks and load cells before they were temporarily stored near the quayside.
Javier de Pablo Arenzana, Sales Manager at Mammoet, highlighted the importance of flexibility in their operations: “Mammoet was able to adapt not only to the schedule but also the surroundings. We have worked in this facility before and helped the client plan and study the route, ensuring the ground was level with steel plates at critical points.”
To transport the monopiles, Mammoet deployed 60 lines of Self-Propelled Modular Transporters (SPMTs) equipped with a specialized cradle system. This system, featuring foldable saddles, supported the monopiles horizontally, minimizing deflections. The SPMTs maneuvered the foundations through various stations and onto delivery vessels via a ro-ro ramp, eliminating the need for cranes.
The most challenging part of the route was the painting station, requiring a 180-degree rotation of the monopiles before entry. In some instances, to avoid delays, freshly painted monopiles bypassed the weighing station if it was occupied, moving directly to storage.
This synchronized logistics effort, involving fabrication, painting, and weighing stages, demanded seamless communication and adaptability to maintain efficiency and avoid disruptions. The result was a smooth and timely operation, showcasing the critical importance of meticulous planning and specialized equipment in the heavy transport sector.
