The Vitruvian Jackup Vessel design was conceptualised in 2022, matured into a fully developed solution by 2025, and is now made ready for commercial deployment.
This state-of-the-art vessel is specifically engineered to handle the transportation and installation of next-generation monopiles weighing up to 5,000 metric tons,
setting a new standard for efficiency and safety in the offshore wind industry.
The next generation of offshore wind turbines, with capacities ranging from 20 to 30 MW, is expected to enter the market between 2029 and 2030. These turbines will be installed in water depths of 40 to 70 meters, necessitating a new generation of monopiles. These monopiles will measure 100 to 130 meters in length, 12 to 15 meters in outer diameter, and weigh up to 5,000 metric tons.
To address these challenges, the Barcelona-based engineering team at Offshoretronic has developed a unique tilting and lifting beam system combined with a roll-on concept. This innovative solution is specifically designed to ensure the safe transportation and installation of next-generation monopiles, which will serve as the foundation for these advanced wind turbines. The system is tailored to handle the immense size and weight of these monopiles, setting a new standard for efficiency and safety in offshore wind installation.
Offshoretronic S.L. has developed an innovative jack-up vessel concept equipped with a unique Tilting & Lifting Beam system, designed to transport and install XXXL monopiles safely and cost-efficiently. This groundbreaking approach eliminates the need for large offshore crane units and expensive mission equipment typically required on floating installation vessels.
The novel concept promises significant cost savings for the transportation and installation (T&I) of monopiles weighing over 3,000 metric tons, addressing the growing demands of the offshore wind industry.
The vessel, marketed under the name VITRUVIAN, is being promoted by Offshoretronic S.L. through its subsidiary company, Windecom. This solution represents a major step forward in optimizing the installation process for next-generation offshore wind foundations.
Background
The next generation of Offshore Wind Turbine Generators (WTGs), with capacities ranging from 20 to 30 MW, is expected to become widely available between 2029 and 2030.
These turbines will be installed in water depths of 30 to 60 meters, with estimates suggesting that 80% will be supported by monopile foundations world wide.
These larger WTG units will require next-generation XXXXL monopiles with dimensions and weights reaching 100 to 130 meters in length, 12 to 15 meters in outer diameter, and weights of up to 3,000 to 5,000 metric tons.
However, many existing wind farm installation vessels are unable to safely perform the transportation and installation (T&I) of XXXL monopiles exceeding 3,000 metric tons. While new and larger crane vessels are needed for offshore installation, vessel contractors and owners are hesitant due to the risk of these expensive assets becoming obsolete before they can generate returns. Therefore, future-proof designs capable of handling monopiles up to 5,000 metric tons are essential.
Current solutions involve building larger monohull installation vessels with single crane units, but these face significant technical and operational limitations in safely handling XXXL monopiles. These monopiles require additional support points during transport, lifting, and installation, further complicating the process. Additionally, the cost of these monohull vessels, including mission equipment, is approaching $600-$800 million USD.
In contrast, our simplified vessel design, combined with a fast-track construction approach, offers a cost-efficient alternative. Our solution is at least 40-50% more cost-effective than new monohull crane vessels and operates at significantly lower OPEX. This design enables vessel owners to build multiple vessels in series to meet global demand for the CAPEX of one single Monohull Vessel.
Key Cost-Saving Factors for a Positive Business Case:
Our innovative approach ensures a future-proof, cost-efficient solution for the installation of next-generation XXXL monopiles, addressing the challenges of the evolving offshore wind industry.
The Concept, Innovations and associated Intellectual Property rights :
The main novel concept, and Offshoretronic have claimed all Intellectual Property rights are the unique Tilting & Lifting Beam (T & L Beam) that will act to Load-out with Roll-on system the Mono-piles and take care of Up-ending and works as a Lifting tool for the safe installation of MP’s up to 5,000 t without and use of any expensive and complex Onshore and/or Offshore Crane units. The main reason we have selected for a Jackup type of vessel is to get optimum control over all the installation processes and work from a very stable platform and eliminate the use of heave compensated gripper systems and/or other expensive and complex mission equipment. Offshoretronic is bringing four (4) main Concepts & Innovations with this new Jackup vessel:
1. The unique Tilting & Lifting Beam that have an intergraded Mono-pile Roll-on system, Up-ending system and Lifting tools with winches.
2. The unique safe horizontal handling of the mono-piles starting at the fabrication yard and the mono-piles will safely be rolled on to our Installation Vessel by new developed transporters with Three unique functions: Roll on, Skiding and Sea-fastening. Inherent risk-prone crane lifts will not be required in the port and/or at the offshore locations and the mono-pile will always stay supported over the full length to prevent buckling risks. To Roll-On the mono-piles, we have installed an innovative module with wheels and can be fitted on the Tilting & Lifting Beam to allow for a smooth Roll-On and Roll-Off at the onshore and offshore location.
3. The safe installation process of handling loads of 5,000 mt. Our lifting winches setup will eliminate any catastrophic risks for loss of the crane’s main hook and/or crane wires. Again, same as with the Load-Out we eliminate buckling risks during Offshore installations and lifting processes as the Mono-pile will be fully supported during the Up-ending and Lifting process elimination any risk of large crane shock-loads by Vessel motions.
4. The unique skidding system of the Mono-pile from and to the T & L Beam and the transverse storage position allowing to load a total of three Mono-piles with an OD of max. 12.5 m or two Mono-piles with OD bigger then 12.5 m up to maximum of 15 m
The Transport and installation Capabilities :
In short, the deck skidding system is integrated with the Roll-on modules that can move in the transverse direction of the Vessel.
This system will allow to Transport 3 x 12,5 m OD MP’s with a total weight of 12.000 mt or 2 x >12,5 m – Up to 15, 5 m OD MP’s with a total weight of 10.000 mt
The skidding system beam will be designed to be fully integrated with the Vessel integral structure to save weight of the Jackup hull unit.