Scaling XXL Monopile Production

How Sif Group Partnered with Davi to Power the Maasvlakte II Factory Expansion

Davi Rolling Technology Powers Sif Group’s Manufacturing Ramp-Up at Maasvlakte II

Story overview

Sif Group partnered with Davi to scale its Maasvlakte II facility with advanced 4-roll and 3-roll plate rolling technology and automation—enabling fast, precise, and safe production of massive XXL monopiles for next-generation offshore wind turbines.

Website

sif-group.com

Location

Netherlands

Industry

Wind Energy

Related products

MCB , MAV , CUSTOM AUTOMATED LINES

The Challenge

Next-generation 15+ MW wind turbines require massive XXL monopiles built from extreme steel plates—up to 170 mm (6.7 in) thick and 15 meters (49.2 ft) in diameter. To meet surging offshore demand at Maasvlakte II, Sif Group needed a high-capacity rolling solution that could rapidly scale output while eliminating major risks like plate slippage, prolonged manual geometry checks, and bottlenecked production cycles.

The Solution

Davi supplied Sif Group with four customized, high-capacity rolling machines—two MCB (4-roll) and two MAV (3-roll variable-geometry)—all specifically engineered for wind energy production. The heavy-duty line integrates automated feeding and clamping systems to eliminate crane dependency, patented Servo-Tronic roll parallelism for uninterrupted synchronization, and the iRoll eXtreme Industry 4.0 interface to automate complex multi-radius sequences with absolute precision.

The Results

Maximum Production Versatility

Combining MCB 4-roll and MAV 3-roll technology provides the perfect balance of speed, high torque, and flexibility for thick-plate wind tower and monopile rolling.

Faster Cycle Times

Automated feeding and smart controls eliminate manual template checks, dramatically speeding up production per shell.

Shortest Flat Ends & Zero Slippage

Direct motorized torque and precise roll positioning maximize material savings and prevent slipping on extreme plate thicknesses.

Enhanced Operator Safety

Full line automation allows operators to handle all loading, feeding, and bending steps from a safe, ergonomic console.

24/7 Industrial Reliability

Built for continuous multi-shift operation, guaranteeing maximum uptime to meet demanding offshore wind targets.

The Technical Credibility Milestone: Production Milestone Achieved at Maasvlakte II

This deep engineering collaboration successfully reached its ultimate validation on the production floor. Davi field technicians completed the on-site installation, commissioning, and final Site Acceptance Tests (SAT) in full alignment with Sif’s expansion schedule. The heavy-duty line is now fully operational at Maasvlakte II, directly powering Sif’s manufacturing ramp-up and consistently delivering XXL monopile shells that meet rigid contract specifications. This achievement adds another key reference to Davi’s global footprint, where we power approximately 70% of the plate roll market in the wind energy sector.

Our partnership with Sif Group confirms our leading role in the offshore wind energy transition. Supplying four of our heavy-duty machines to one of the world’s most sophisticated monopile factories demonstrates that Davi technology provides the reliability and throughput necessary for the industry to reach its targets.

Stefano Santoni

Wind Energy Division Director

Operational updates