A new German research and industry initiative, OptiMP, is aiming to reduce steel consumption and extend the service life of monopiles used in offshore wind foundations, as the sector looks to improve cost efficiency and sustainability.
Monopiles, which can exceed 100 metres in length and 15 metres in diameter, typically require more than 2,000 tonnes of steel per unit and involve energy-intensive welding processes. Current designs are generally limited to a 30-year operational lifespan due to mechanical stress and corrosion.
The OptiMP initiative, supported under Germany’s 8th Energy Research Programme, brings together industrial and research partners including the Fraunhofer Institute for Large Structures in Production Engineering, Leibniz University Hannover, JBO Engineering Group, Grillo Zinc Metals, and Vattenfall Europe Windkraft.
“Through targeted improvements at all process stages, we expect to achieve steel savings of up to ten percent and extend service life by up to 30 percent,” said project manager Marc Thiele of BAM.
The consortium will focus on optimising weld seams and free edges—critical areas for improving fatigue strength and corrosion resistance. New post-treatment methods, non-destructive crack detection, and advanced load simulation techniques are also part of the project scope.
“In close cooperation with partners from industry and certification, we aim to quickly incorporate the project results into standardisation and thus accelerate their transfer into industrial practice,” Thiele added.
Supporting organisations include EEW Special Pipe Constructions, Siemens Gamesa, EnBW, ZEISS/GOM, Skyborn Renewables, and certification body DNV.
The initiative reflects growing industry pressure to lower the carbon and material footprint of offshore wind infrastructure as deployment scales up across Europe.
