Offshore foundations

Ever since the start of erecting windfarms offshore, ITW Engineered Polymers' UHPC material Ducorit® has been a crucial structural component of foundations for offshore wind turbines, substations and met masts.

Ducorit® is successfully applied as a reliable, strong and cost-effective connection between piles and transition pieces.

    

Monopiles

75% of the capacity installed or under construction offshore is based on the monopile concept whereby transition pieces are grouted to piles by applying Ducorit®.

A monopile foundation consists of a steel pile driven into the seabed and a transition piece slid onto or into the pile. After adjustment of the verticality of the transition piece, the space between pile and transition piece is grouted with Ducorit® which is mixed and pumped through flexible hoses into the annulus.

 

Tripile

A tripile foundation consists of three steel piles driven into the seabed after which a three-legged transition piece structure is slid into the three piles. The overlaps between piles and transition piece are grouted with Ducorit®.

The Ducorit® connections evenly distribute the forces from the three-legged transition piece to the piles.

Presently, ITW Engineered Polymers provides turnkey grouting services to Bard Engineering's patented tripile foundations at their wind farm in the North Sea.

 

Densit Offshore Renewables Brochure

 

Tripod

A tripod support structure/foundation is secured in place by driving threepiles into the seabed through a sleeve in each of the three corners.

Ducorit® is pumped into the annuli between pile and sleeve to ensure a strong and durable connection.

When erecting the Alpha Ventus wind farm in the North Sea, ITW Engineered Polymers grouted six tripod foundations for the 5 MW wind turbines.

Turnkey Solutions

All ITW EP offshore foundation installations come with a complete grouting service which includes consultancy, design, planning, and supply of grouting material, installation, test sampling and documentation for any offshore structure design and installation scheme.

  • Project Management - Grouting projects are always handled by a project manager and a leading supervisor who ensure that the projects are carried out safely, according to QHSE standards and on time.  The grouting installation/application is verified by Det Norske Veritas (DNV) and Germanische Lloyd (GL).
  • Skilled and Experienced Supervisors - The supervisors working offshore are skilled, experienced, and dedicated to providing the best possible service to our customers.  Throughout a grouting installation/operation, our supervisors take samples according to a strict quality plan for testing and documentation.
  • Optimized Offshore Equipment - Over the years, we have developed specialized equipment for grouting offshore to ensure our customers an efficient and cost-effective installation.  The grouting equipment fulfills the requirements for quick mobilization and the design takes the limited space at the installation vessels into consideration.

 


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