PROJECT: Research into the structural integrity of floating offshore wind systems using Artificial Intelligence-based models.
ACHIEVEMENT: Development of organic and hybrid coatings for corrosion and biofouling protection to support degradation models.
The objective of the Strategic Hazitek INTEGRIA project (ZE-2023/00026), funded under the HAZITEK 2023 programme, is to develop a comprehensive digital model consisting of multiple Artificial Intelligence (AI)-based models covering the key structural components of floating offshore wind turbines, including the transition piece (TP), mooring system, power transmission and distribution systems, access systems, and hydraulic and mechanical systems used to control the floating wind turbine.
The project is led by Nautilus Floating Solutions, and the consortium comprises 12 companies and three technology centres: Alerion, Ceit Technology Centre, CIDETEC, CoreMarine, DITREL INDUSTRIAL S.L., ERREKA, GLUAL ENERGY, HINE GROUP, Ibermática, INNOMAT, KERA-COAT, LAULAGUN BEARINGS, NAVACEL PROCESS INDUSTRIES S.A., and TECNALIA.
The marine environment is one of the most aggressive operating environments, combining harmful chemical agents such as chlorides with high levels of cyclic stress and fatigue generated by waves, wind, and continuous rotor blade movement throughout the service life of offshore structures.
In floating offshore wind applications, not only the structures themselves but also the mooring systems must achieve a service life of at least 25 years. Failures are typically caused by improper installation or corrosion, making it essential to select appropriate structural materials, fastening systems, and protective coatings, while accurately assessing fatigue, corrosion, and stress levels to minimise maintenance requirements.
Current coating systems used in the offshore wind sector are generally based on thick multilayer systems (≥350 µm), resulting in high material consumption and significant environmental impact.
In this context, the project seeks to develop advanced protection solutions that provide not only corrosion resistance but also wear resistance, extending component service life while simplifying maintenance operations. Current research focuses on Direct-to-Metal (DTM) coatings capable of meeting performance requirements in a single layer, thereby reducing total coating thickness and eliminating adhesion issues between multiple layers. Research also includes the development of bio-based coating components to reduce environmental impact, together with repaintable coating systems that simplify maintenance without requiring the removal of existing coatings.
Another key consideration in floating offshore wind is the environmental sustainability of coating systems. Increasing coating durability and service life should not result in a greater environmental footprint, making life-cycle sustainability a fundamental design criterion.
For INNOMAT, the project's primary objective is not only to develop new organic and hybrid coating formulations that improve durability and reduce maintenance requirements, but also to design an organic coating system combined with a hybrid primer layer, together with an industrial application and curing process specifically adapted and optimised for floating offshore structures.
To validate these innovations, the NAUTILUS floating platform will serve as the main case study, while HarshLab, located at BiMEP and operated by TECNALIA, will be used as the offshore laboratory for validating the technologies developed within the INTEGRIA project.
The project is funded by the Basque Government's Department of Economic Development, Sustainability and Environment through the HAZITEK 2023 Programme, with co-funding from the European Regional Development Fund (ERDF).