CASE

Monopile transport & structural integrity

In large-scale offshore wind projects, monopiles represent a critical structural component – and ensuring their integrity from fabrication to installation is essential

Structural optimization of monopiles

In this project, Flindt Kristensen Engineering developed a comprehensive engineering approach to evaluate and safeguard the structural performance of monopiles throughout their entire lifecycle.

From the earliest production stages, we conducted detailed structural assessments of the monopile, with particular focus on welded connections.

Using advanced FEA methodologies, we modeled the weld geometry and incorporated elements that accurately represent weld stiffness.

This level of detail enables a more realistic stress distribution, allowing optimization of weld design and reduction of costly and time-consuming manual welding processes—without compromising structural performance.

Analysis of transport and handling of monopiles

Beyond production, we analyzed the internal logistics and transport of monopile sections using SPMTs (Self-Propelled Modular Transporters).

These analyses included critical scenarios such as emergency braking and unexpected dynamic loads. By simulating these events, we gained valuable insights into load paths and stress concentrations, enabling safer and more controlled handling procedures.

This knowledge has directly contributed to the development of adaptive transport cradles in subsequent projects. These cradles are designed to conform to the monopile geometry, distributing loads more evenly and minimizing local stress concentrations during transport and storage.

Lifting configurations and transport design

In addition, we evaluated multiple lifting configurations, including J-hook lifting and bottom-supported sling (belly lift) methods. Each scenario was analyzed to ensure structural integrity under realistic load cases, while also considering operational efficiency and safety.

For offshore transportation, we designed and verified transport cradles suitable for sea transport and assessed the dynamic accelerations induced by various vessel types. This included evaluating the monopile response to wave-induced motions and ensuring compliance with transport criteria across different shipping conditions.