EEW Group Wind Energy Monopile Manufacturing Facility

New offshore wind manufacturing facility produces massive monopiles that are the bedrock of New Jersey’s clean energy industry

Our Client’s Challenge

Specialized welded steel pipe producer EEW Group’s monopile manufacturing facility is propelling New Jersey forward as a clean energy industry leader. Situated on 200 acres in the Paulsboro Marine Terminal along the Delaware River, the facility is the first significant offshore wind energy supply chain investment in the Northeast. The $250 million facility is making advancements in mitigating the effects of climate change.

The space produces the world’s largest steel monopiles, each 40 feet wide, 400 feet long, and weighing over 5 million pounds. On its side, a monopile’s width could accommodate a two-lane highway and be high enough to fit a four-story building. Once the monopiles make their way to the Atlantic Ocean via ports and rivers, they are driven into the seabed. They will support the towers, blades, and turbines that will fuel offshore wind farms along the coast of southern New Jersey.

Our Solution

Construction began in January 2021 after the team broke ground on the first of six manufacturing buildings. The 82,000-square-foot circumference welding building with an attached 14,000-square-foot office building was completed in 2022. Other buildings, expected to be completed in 2023 and beyond, include two paint and blast, fire pump, roll bending, and segment welding structures, totaling over 225,000 square feet.

Gannett Fleming provided electrical, mechanical, plumbing, fire protection, HVAC system design, and other engineering design services for the circumference welding, two paint and blast, and fire pump buildings.

Air handling units heat and cool different spaces within the building to temperatures specific to manufacturing activities and supply fresh air to the workers. Electrical panels provide power to the welding and painting equipment. Generators ensure a steady power supply, allowing production to continue uninterrupted.

The project exemplifies Gannett Fleming’s commitment to sustainable practices and passion for renewable energy. Creating hundreds of long-term manufacturing jobs demonstrates the positive impact of the clean energy technology industry on local economies.

Key Features

The facility is the largest of its kind in the U.S.
The concrete platforms on which the monopiles are assembled have been reinforced to withstand the sheer weight of the massive steel structures.

Awards & Recognition

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Outcomes

The new facility is the manufacturing and support center of the emerging multibillion-dollar offshore wind industry.
Monopile production in the facility will create hundreds of manufacturing jobs, boosting the local economy.