Wind Tower and
Monopile Production

Driving wind
energy forward.

Streamlining Wind Tower and Monopile Production

Helping manufacturers in the wind energy industry increase their weld production and quality, since 2002. We design, manufacture and deliver hard automation solutions for onshore / offshore wind tower and monopile production. As your trusted automated ally, we’re here to help you dominate the market with ‘monopoly production’ solutions that redefine efficiency and quality.

Jesper Hansen, Global Technical Sales Manager for the Renewables Division at Key Plant Automation

Weld automation solutions
for the wind energy sector.

From Start to Finish, We are with you Every ‘Section’ of the Way

“With our expertise, knowledge and capabilities – we deliver innovative solutions to benefit our customers needs. As a global leader, and the UK’s only major manufacturer of hard automation systems for the wind energy industry, we offer customers around the world the full range of solutions and services available.”

Jesper Hansen

Global Technical Sales Manager
(Renewables Division)

Factory Layout

Our forward-thinking factory layouts are designed to enhance efficiency and capacity, maximising throughput for wind towers and monopiles.

Welding

Increase deposition rates, productivity, and arc-on time with our cutting-edge column and boom welding manipulators and seam welding systems.

Fit-Up Systems

Achieve unparalleled welding quality and consistency with our linear precision fit-up and growing line systems.

Rotators / Turning Rolls

Choose from our conventional, self-aligning, and anti-drift rotator solutions, engineered to meet all wind tower and monopile diameter and capacity requirements.

Internal Transport

Our innovative transfer and tilting transfer systems make maneuvering cans and sections easy, efficient, and safe.

Optimisation

Count on our dedicated specialists to optimise your wind tower and monopile production processes, ensuring peak performance.

Wind tower production.

Elevate Your Wind Tower Production with Automation Excellence

Are you ready to take your wind tower production to new heights? Our state-of-the-art automated fit-up and growing line systems are meticulously engineered to empower you to control costs and set new benchmarks for weld and production standards.

Precision Engineering: Manufactured with precision and expertise, our growing line systems are engineered to perfection. They ensure that every weld and production process meets the highest standards of quality and accuracy.

Tailored to Your Needs: We understand that every wind tower project is unique. That’s why our growing line systems are purpose-built to meet your specific project requirements. Whether you’re working on onshore or offshore wind towers, our systems adapt seamlessly to your needs.

Cost Control: Controlling costs is essential in the competitive wind energy industry. Our automated solutions streamline your production process, reducing labor costs, minimising errors, and optimising resource utilisation.

Enhanced Efficiency: Efficiency is at the core of our growing line systems. They enable you to boost productivity, reduce downtime, and accelerate your project timeline, ensuring you meet your deadlines with ease.

Quality Assurance: Maintaining impeccable weld and production standards is non-negotiable. Our systems are equipped with quality control mechanisms to ensure that every component produced meets or exceeds industry standards.

Safety First: Safety is paramount in any production environment. Our growing line systems are designed with safety features to protect your workforce and assets.

Part of a Key Plant Automation wind tower production system for the offshore industry

Monopile production.

Foundations Built to Last

When it comes to the foundations of wind towers, we understand that strength, precision, and reliability are paramount. At Key Plant Automation, we’ve got you covered. Our automated systems are engineered to handle the extra heavy, thick-wall steel tube foundations of wind towers, ensuring your projects stay on solid ground.

Unrivaled Strength: Monopiles serve as the sturdy foundation for wind towers. Our systems are built to handle vessels weighing over 2000 tonnes, ensuring the stability and resilience required for even the most challenging conditions.

Precision Engineering: Each monopile is a testament to precision and expertise. Our automated systems guarantee that every weld and component is manufactured with meticulous attention to detail, meeting the highest industry standards.

Efficiency in Action: Efficiency is at the heart of our systems. By automating the production process, we reduce labor requirements, minimise errors, and optimise resource utilisation, all of which contribute to cost savings and faster project timelines.

Quality Assurance: We understand that the quality of each monopile directly impacts the reliability of the entire wind tower. Our automated systems are equipped with stringent quality control mechanisms to ensure that every foundation is flawless.

Safety First: Safety is non-negotiable in any production environment, especially one as demanding as monopile manufacturing. Our systems are designed with safety features to protect your workforce and assets.

Part of a Key Plant Automation monopile production system for the offshore industry
Column and boom welding manipulator for wind tower production

Column and Booms

Our automated welding processes cover inner, outer, circumferential, and longitudinal welding applications, providing unmatched precision and efficiency.

Self aligning rotators designed for wind tower production

Rotators / Turning Rolls

Maximise safety, minimise handling, boost productivity, and enhance welding quality with our rotators and turning rolls.

Fit up and Growing line system commissioned for a customer in the offshore wind energy sector

Fit-Up / Growing Lines

Reduce time and cost, increase productivity, and ensure consistency in the fitting up and joining of cans with our fit-up and growing line systems.

Specialised headstock and tailstock system designed and manufactured by Key Plant Automation

Customised Solutions

We take pride in offering end-to-end solutions, from plate delivery to site installation and commissioning. Our in-house design and manufacturing capabilities allow us to create highly sophisticated hard automation solutions tailored to your unique needs.

Column and boom welding manipulators designed for wind tower production
Circumferential seam welding of flange in wind tower production facility

Traversing extra heavy duty 7m x 6m tandem circumferential seam column & boom welding system.

Proud contributors to wind
energy projects worldwide.

Since 2002, Key Plant Automation has been dedicated to driving innovation in wind tower and monopile production. We are proud to have played a pivotal role in wind energy projects across the globe, helping manufacturers streamline their production goals and contribute to a sustainable future.

Contact us today to explore how our automated solutions can transform your wind tower and monopile production, helping you stay ahead in the offshore wind energy industry. Together, we can harness the power of the wind to shape a more sustainable tomorrow.