Mass Production and Manufacturing Line

The local production of concrete floating foundations, located near the future floating wind farm sites, is a strategic lever to reduce both the cost and carbon footprint of the substructures, while maximizing the socio-economic benefits for the local regions.

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Fos-sur-Mer: An Innovative Project to Meet the Floating Wind Demand in the Mediterranean 

BW Ideol continues its expansion in the Mediterranean by conducting a feasibility study for establishing a serial production line for concrete floating foundations in Fos-sur-Mer (FOS3F), with the aim of maximizing the use of local content. The feasibility study, funded by the French Ademe under the France 2030 initiative and completed by the end of 2024, validated the relevance of such a concrete floating foundations factory and confirmed its economic competitiveness as well as its positive impact on the local industry and socio-economic benefits. 

A Turning Point for the Floating Wind Industry 

The production line at Fos-sur-Mer would be dedicated to manufacturing concrete substructures based on BW Ideol’s innovative and patented Damping Pool® concept, the only proven concept at sea on two continents, designed to meet the needs of current (15MW+) and future (20MW+) floating wind projects. The feasibility study confirmed the robustness of local concrete floating foundations production, surpassing other available execution schemes and offering competitiveness by reducing costs and logistical risks while maximizing local economic returns. 

This serial production line, ideally located in the South of France and on the Mediterranean coast, will meet the needs of various floating projects in France, Spain (East Coast), Italy, and Greece, contributing to the growth of renewable energy in Southern Europe. 

Minimized Environmental Impact 

This project is part of a sustainable and responsible approach towards the environment. The future factory plans to prioritize short supply chains, sourcing materials directly from local cement plants and quarries, and producing a low-carbon concrete mix on-site. All components of the floating foundations, except for a small amount of aluminum, are recyclable to over 95%. Additionally, BW Ideol continues to strengthen its Research & Development efforts through the Velella project, supported by the French Ademe. One of the aims of this project is to find the best ways to recycle or upcycle concrete that has been submerged in seawater for several years, as well as the components of the mooring system. 

The raw materials will be transported to the factory mainly by rail, thereby reducing the carbon footprint associated with their transportation. Prioritizing rail transport also helps reduce road traffic in an area already congested with trucks, minimizing the impact on local residents. 

Finally, by using concrete instead of steel, this production line would also lead to substantial CO₂ savings, with an estimated reduction of 30% compared to steel floaters manufactured abroad. The impact on the carbon footprint is even greater when considering only the construction phase: the FOS3F project demonstrates a 45% reduction in carbon emissions compared to a semi-submersible steel foundation manufactured in Asia and shipped to Europe for final assembly.

A Project Driving a Positive Energy Transition for Local Communities

The establishment of this serial production line in Fos-sur-Mer is fully aligned with the European energy transition strategy. By locally producing the necessary foundations for wind farms, this project reduces dependency on imports and strengthens the competitiveness of renewable energy solutions throughout the Mediterranean region. 

The production line at Fos-sur-Mer will also be a driving force for the local economy. It will generate the creation of 1,300 direct jobs, both skilled and unskilled, contributing to a positive energy transition for the region. 

Adaptability and Replicability: A Flexible Production Line for the Future 

This production line is designed to be easily adaptable to the needs of larger floating foundations, compatible with 20 MW+ turbines and beyond. Moreover, it can be replicated. With minimal port modifications and limited requirements, this manufacturing line can be established in numerous ports.