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

At Sif, we’ve been building trust, craftsmanship and progress since 1948. What started with pressure vessels has evolved into complete foundations for offshore wind. From our sites in Roermond and Maasvlakte 2, we contribute daily to the energy transition. In line with our growth and ambitions, we’ve been listed on the stock exchange since 2016.

Website

sif-group.com

Location

Netherlands

Industry

Wind Energy

Related products

MCB , MAV , CUSTOM AUTOMATED LINES

The Challenge

As offshore wind turbines reach capacities of 15 megawatts and beyond, foundation structures are scaling to unprecedented sizes. To anchor these massive turbines, manufacturers are transitioning to extra-large (XXL) monopiles. These structures demand steel plates of extreme thicknesses—often between 50 mm and 170 mm (2" to 6.7")—and diameters stretching up to 15 meters (49.2 ft).

For global offshore foundation pioneers like Sif Group, expanding manufacturing capacity to capture this market is a massive industrial undertaking. At their landmark Maasvlakte II facility in Rotterdam, the Netherlands, Sif required a heavy-duty rolling system capable of a rapid production ramp-up. When dealing with steel sheets of this magnitude, the manufacturing risks are exceptionally high. Fabricators face significant bottlenecks, including plate slippage, prolonged cycle times due to repetitive manual geometry checks, and the challenge of maintaining perfect roundness across thick tapered sections. To protect their project pipeline, Sif needed a reliable solution to mitigate risk and guarantee operational continuity.

The Solution

High-Capacity MCB Bending Technology and Smart Feeding Infrastructure

To support Sif Group’s manufacturing ramp-up, Davi supplied and commissioned a custom, high-productivity heavy rolling line centered around our heavy-duty MCB (Four-Roll Plate Roll) technology.

The custom-engineered line integrates:

Advanced Material Handling and Feeding Systems: Heavy-duty vertical positioning units and automated side supports that securely clamp and stabilize the massive plates during the entire rolling cycle, removing the reliance on standard shop cranes.
The Patented Servo-Tronic Parallelism Control: A dual, independent hydraulic and mechanical control system that keeps the rolls parallel at all times. Even in the case of a temporary electronic failure, the system mechanically maintains synchronization, protecting the machine and the workpiece from damage and eliminating unplanned outages.
iRoll eXtreme Industry 4.0 Interface: An advanced control console equipped with dedicated software that automates complex multi-radius sequences, ensuring the highest level of process repetition.

The Results

Time Reduction and Labor Savings

Automated feeding and precise control remove the slow trial-and-error process of using manual cardboard templates or visual sweep checks, drastically lowering cycle times per can.

Shortest Flat Ends and Zero Slippage

Motorized rolls provide optimum torque transmission directly to the plate. Operators can pinch the sheet exactly at the tangent point to achieve the shortest flat end, saving material and preventing plate slippage during pre-bending.

Enhanced Operator Safety

All lifting, feeding, and positioning steps are handled through the synchronized line, keeping the operator at a safe distance at the ergonomic console.

Long-Term Operational Reliability

Built on robust frames with premium, easily sourceable commercial components, the system minimizes maintenance downtime and ensures high machinery availability over a multi-shift, 7-day operational week.

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