The OWSplus final report documents a multi‑partner effort to advance the manufacturing of floating offshore wind foundations (FOWF). The core partner, EEW Special Pipe Constructions GmbH (EEW SPC) of Rostock, has long been a leader in producing monopile foundations for offshore wind turbines, with a production capacity for longitudinally welded steel pipes up to 12 m in diameter, 120 m in length and 2 500 t in weight. In the OWSplus project, EEW SPC focused on the design, virtual testing and integration of a range of production equipment specifically tailored to the unique demands of floating foundations.
Technical outcomes of the project include the development of a comprehensive methodology for the design and assessment of lifting and turning rigs, transport and storage systems, and coating processes for floating structures. Finite‑element analyses were employed to evaluate local stresses during transport of pipe sections and to assess the behaviour of a spar‑buoy structure under varying hull diameters. The study produced a matrix of plate thicknesses and pipe diameters with corresponding D/t ratios, enabling optimisation of structural weight while meeting safety and regulatory requirements. A detailed process flow for the manufacturing of radial stiffeners integrated into the hull was established, together with a decision matrix for evaluating construction methods against criteria such as cost, build time and structural performance.
Coating technology was addressed through a systematic assessment of safety, health and environmental aspects. The project defined a coating process flow that incorporates legal and regulatory constraints, and demonstrated the feasibility of applying protective layers to large‑scale floating components. Laser scanning and 3‑D robot vision were used to monitor weld quality and to track the progression of arc‑weld seams, ensuring compliance with industry standards.
Transport and handling solutions were also a key deliverable. A modular transport and handling system based on self‑propelled modular transporters (SPMTs) was designed, including a pad‑eye mounting concept for the movement of head sections. Local load analyses for transport modules were compiled, providing a basis for the safe movement of large structural elements across the production site. The project also produced a process flow for the final assembly stage that incorporates conservation measures, ensuring that the finished floating foundation meets performance targets.
The collaboration involved several partners beyond EEW SPC. Neptun Ship Design GmbH (NSD) contributed expertise in ship‑building design, while Neue Warnow Design & Technology GmbH (WDT) supplied advanced manufacturing technologies. The consortium operated under the OWSplus programme, funded by the German federal government’s offshore wind strategy, with a project duration of approximately three years. The partners coordinated through joint workshops, virtual simulations and iterative design reviews, ensuring that the developed equipment and processes aligned with industry workflows and regulatory expectations.
In summary, the OWSplus project delivered a suite of validated manufacturing tools and methodologies that enable EEW SPC to produce floating offshore wind foundations more efficiently and safely. The technical results—ranging from structural optimisation and coating processes to transport and handling systems—provide a solid foundation for industrial deployment. The collaborative framework, supported by federal funding and industry‑research integration, positions the consortium to transition these innovations from prototype to commercial production, potentially securing patents for the novel equipment and processes developed during the project.