The first batch of monopiles – steel foundations for the Baltica 2 project implemented by Ørsted and PGE – has left the production hall. Monopiles are key load-bearing elements of the entire wind farm – they carry the loads of the turbines and sea waves, and the precision of their manufacture and assembly directly translates into the reliability and efficiency of the installation.

A total of 111 monopiles (107 for turbines and 4 for offshore transformer stations) are planned for the Baltica 2 project, with a diameter of 7.5-10.5 metres and a wall thickness of 60-112 mm, depending on the requirements of the target foundation location. The manufacturing process includes, among other things, sheet rolling, circumferential and longitudinal welding, a full package of non-destructive testing (NDT) and the application of multi-layer anti-corrosion coatings. The completion of the first batch opens the way for preparations for sea transport and acceptance of subsequent sections. At the same time, quality control and coating work are ongoing. Monopiles for the Baltica 2 project will be supplied by two companies – EEW and Steelwind. EEW will manufacture 77 monopiles. The first loading of finished foundations onto a transport vessel is scheduled for the end of 2025.

– Monopiles are one of the most demanding elements of offshore investments. We are talking about structures up to 100 metres long and weighing around 1,900 tonnes, with a lifespan measured in decades. During today’s visit to the EEW factory, we were able to see for ourselves the scale of this enormous undertaking and take a look at the advanced technological processes. We were very enthusiastic to hear that the production of monopiles is proceeding according to schedule. As the flagship offshore wind energy project in Poland, Baltica 2 also remains a key element of Ørsted’s global construction portfolio and our programme to build 8.1 GW of offshore wind farms between 2025 and 2027 – said Patrick Harnett, Chief Construction Officer / Executive Vice President, Ørsted.

Poland is rapidly developing its industrial base for offshore wind energy. The vast majority of additional steel structures for the Baltica 2 project foundations are being manufactured in Poland. They will be supplied by the Baltic Industrial Group and Smulders.

– Monopiles are exceptionally spectacular structural elements of offshore wind farms in terms of size. The start of their production for the Baltica 2 project is a clear signal that we are approaching the stage of the first installation works at sea. The first activities, including cleaning the Baltic Sea bed and preparing the infrastructure, are already underway. In the next stage, we will begin driving the foundations on which 107 wind turbines, each 250 metres high, and four offshore transformer stations will stand. Our goal is for energy from Baltica 2 to flow to Polish homes in the second quarter of 2027 – said Maciej Górski, Vice-President of the Management Board of PGE Polska Grupa Energetyczna for Operations.

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

Baltica 2 – jointly developed by PGE and Ørsted – will be the largest offshore wind farm built in Polish Baltic waters. After its launch in 2027, it will reach a capacity of up to 1.5 GW, which will allow it to supply green energy to approximately 2.5 million households in Poland.

Source: Baltica 2