The first batch of monopiles for Baltica 2 rolls off factory floor

The first batch of monopiles – steel foundations for the Baltica 2 project, developed by Ørsted and PGE – rolled off factory floor. Monopiles are the key load-bearing elements of the entire offshore wind farm – they transfer turbine and wave loads, and the precision of their manufacturing and installation translates directly into the reliability and performance of the installation. 
A total of 111 monopiles (107 for turbines and 4 for offshore substations) are planned for the Baltica 2 project, with diameters between 7.5 and 10.5 meters and wall thicknesses of 60-112 mm, depending on the requirements of the target foundation location. The manufacturing process includes, among other things, plate rolling, circumferential and longitudinal welding, a full suite of non-destructive testing (NDT), and the application of multi-layer anti-corrosion coatings. The completion of the first batch opens preparations for marine transport and acceptance of subsequent sections. In parallel, quality inspections and coating works are underway. The monopiles for the Baltica 2 project will be supplied by two companies: EEW and Steelwind. EEW will supply the project with 77 monopiles and the first load-out of completed foundations onto a transport vessel is planned for the end of 2025. 

— Monopiles are among the most demanding components of offshore projects. We are talking about structures up to 100 meters long and weighing around 1900 tonnes, with durability measured in decades. During today’s visit to the EEW factory, we were able to see first-hand the scale of this vast undertaking and examine the advanced technological processes. We were very pleased to learn that production of these components is progressing on schedule. As Poland’s flagship offshore wind project, Baltica 2 also remains a key part of Ørsted’s global construction portfolio and our 8.1 GW offshore wind construction programme for 2025 to 2027 - said Patrick Harnett, Chief Construction Officer / Executive Vice President, Ørsted.
 
In Poland, the industrial base for offshore wind is developing rapidly. Vast majority of secondary steel structures for the Baltica 2 foundations are being manufactured in Poland. They will be supplied by the Baltic Industry Group (Grupa Przemysłowa Baltic) and Smulders. 

Monopiles are exceptionally spectacular structural components of offshore wind farms due to their size. The start of their production for the Baltica 2 project is a clear sign that we are approaching the stage of initial offshore installation works. The first activities, including seabed cleaning and infrastructure preparation in the Baltic Sea, are already underway. In the next phase, we will begin driving the foundations that will carry 107 wind turbines, each 250 meters tall, and four offshore transformer stations. Our goal is to deliver energy from Baltica 2 to Polish homes by the second quarter of 2027 – said Maciej Górski, Vice-President of the Management Board for Operations, PGE Polska Grupa Energetyczna.

In parallel to the preparatory work at sea, construction work is underway on the onshore part of the project. In the Choczewo commune, the onshore connection infrastructure is being built - onshore substation and HDD drillings which will enable the connection of the offshore and onshore parts of the cables. The works are carried out in accordance with the highest QHSE standards, with an emphasis on solutions that reduce the carbon footprint (including waste reduction, efficient energy use, and long-lasting coating systems).

Baltica 2 – developed jointly by PGE and Ørsted – will be the largest offshore wind farm built in Polish waters of the Baltic Sea. Once commissioned in 2027, it will reach up to 1.5 GW of capacity, supplying green energy to around 2.5 million households in Poland.


Media contacts:

Beata Głuszcz
Head of Communications
Ørsted Poland
beagl@orsted.com
+48 57 341 25 37

Marcin Poznań
Spokesperson
PGE Baltica
marcin.poznan@gkpge.pl
+48 887 856 620