As offshore wind turbines grow larger and project scales expand, the demands on every component—especially bolted connections—are intensifying. Gaizka Arregi, Commercial Manager at ERREKA Smart Fastening, discusses how decades of experience, digital monitoring, and automation are reshaping joint integrity, driving efficiency, and defining the future of offshore engineering.
Larger turbines mean greater static and dynamic loads. The challenge lies in optimizing bolted connections from every angle: size, cost, and handling. A holistic approach is essential, covering joint design, tightening tools, handling procedures, and the reliability required to meet increasing load demands.
ERREKA's 64 years of experience have led to an engineering-focused approach that optimizes the design, tightening, and maintenance of these critical connections. "We manufacture and sensorize in-house, streamlining the process for our customers," says Arregi.
Offshore environments are notoriously harsh. Design must reflect this reality. ERREKA employs advanced coatings to protect against corrosion, ensuring reliable performance in demanding marine conditions.
The East Anglia THREE (EA3) project, one of the world's largest offshore wind farms, is a prime example. Delivering 1.4 GW of capacity, it requires over 13,000 M90 bolts—some of the biggest ever attempted offshore. This project highlights a critical shift: the challenge is no longer just scaling up, but designing more compact joints that withstand the same loads.
Sensor-enabled fasteners are transforming joint integrity. By providing real-time insight into bolt performance, systems like EDB enable more efficient flange designs optimized for actual load conditions.
Simulation and digital modeling are also reshaping the sector. ERREKA uses simulation to define optimal tightening strategies for both preload quality and time efficiency, validating them on full-scale test benches before offshore deployment.
True offshore installation costs often lie in logistics. For EA3, ERREKA developed a solution that significantly reduces the time needed for the temporary assembly of the transition piece (TP) onto the monopile (MP), streamlining operations.
Furthermore, training is vital. ERREKA provides hands-on training for both its personnel and client operators using full-scale test rigs. "Knowledge transfer through real-world simulation and expert guidance builds confidence, reduces errors, and ensures long-term reliability," Arregi notes.
Looking ahead, the next frontier is monitoring and automation. By installing 100% sensorized bolts, lifecycle costs can be reduced by tightening only those that require intervention. Remote monitoring via custom dataloggers integrated with SCADA systems eliminates unnecessary offshore trips and enables smarter maintenance planning.
"This evolution will ensure consistent preload, reduce human error, and enable smarter, data-driven maintenance strategies," concludes Arregi.