Deep foundations for an Offshore Windfarm – A challenge not only to dive-drill from seabed

In October 2023 Bauer has completed the execution of deep foundations for the Saint-Brieuc offshore wind farm 16 km off coast north of France. Once operational, the 496MW wind farm will generate enough clean energy for 835,000 inhabitants. Ailes Marines, owned by Iberdrola, contracted Van Oord who deployed Bauer. In total, 190 shafts have been drilled and the same number of pin piles were grouted to support 62 wind turbines, based on triple jackets, and an offshore substation, based on a four-pile jacket. Bauer did the works from Van Oord’s offshore installation vessel called “Aeolus”. The Atlantic environmental conditions in combination with the extremely hard and rocky seabed and high requirements to geometrical tolerances and other key quality indicators challenged the contractor’s expertise and equipment in several ways. The paper shall illustrate the planning, execution and particular solutions to meet the client’s demands to their full satisfaction. First of all, an innovative drilling method was used to install the foundations for which project-specific “dive drills” were engineered and constructed by Bauer. Secondly, the underwater survey tasks needed smart solutions and skilled personnel to prove the accurate final position of the pin piles. The survey must ensure the precise position of the newly designed drilling template, which functioned as a positioning and casing drilling tool, but also the subsequent placement of the pin piles. Last but not least, the pin piles inserted into the shafts needed a fixed and force-locked connection with the ground. Great efforts were done to get to the necessary fresh and hardened properties of the cementitious grout itself, and to control the complete filling and necessary integrity of the structural sleeve grouting. All above three aspects, the dive-drill method, the underwater survey and the sleeve grouting will be explained in detail and challenges experienced offshore will be showcased. Eventually, a full set of individual expert features for drilling, monitoring and grouting techniques have been developed towards an optimized installation system of which parts have been already introduced into other fields of geotechnical works. Accepting challenges based on passion for progress for this outstanding project has brought innovative techniques and features into the deep foundations industry with great potential for adaptions in other fields of geotechnical works.