Scaling Up to XXL Foundations

Fabrication Insights from Idesa and Davi

Offshore Fabrication: Lessons from IDESA and Davi

Story overview

Founded in 1993, Spain’s IDESA has grown into a global leader in designing and fabricating static and modular equipment for the energy sector. To tackle the extreme manufacturing demands of next-generation offshore wind structures, IDESA partnered with Davi to integrate high-capacity, heavy-duty plate rolling technology built for maximum precision and reliability.

Website

https://www.idesa.net/index.php

Location

Spain

Industry

Wind Energy , Oil & Gas and Nuclear

Related products

MCB , CUSTOM AUTOMATED LINES

The Challenge

Scaling offshore wind turbines past 15 MW means bending heavy-walled steel plates over 100 mm (4 in / ~3.94 in) thick—where massive bending forces cause machine deflection and frame distortion. This creates "camber" defects on cylindrical shells, leading to severe welding misalignments, costly rework, and project delays.

The Solution

IDESA integrated Davi’s high-capacity MCB 4-Roll Plate Roll to eliminate structural deflection. Combining 4-roll technology for continuous top-and-bottom plate clamping with Servo-Tronic parallelism control and high-torque planetary drives, the MCB guarantees pinpoint accuracy, eliminates plate slippage, and delivers maximum uptime without machine distortion.

The Results

Eradicated Rework

Continuous clamping and rigid machine geometry deliver exact tolerances, ensuring seamless fit-up for longitudinal and circumferential welding with zero manual corrections.

Shortest Flat Ends

Pre-bending between the top and bottom rolls pinches heavy plates with extreme precision, minimizing flat ends, saving material, and dramatically shortening cycle times.

Enhanced Safety & Productivity

Single-pass rolling under full CNC control automates heavy-plate forming, boosting shop throughput while keeping operators safely away from moving components.

The Technical Credibility Milestone: Over 300 Global Wind Industry References
Davi’s vertical industry expertise is backed by more than 300 heavy-duty installations operating across the global wind energy sector, representing roughly 70% of the plate roll market for wind tower and foundation manufacturing. Every heavy-duty system is designed and manufactured under strict certifications (ISO 9001, ISO 14001, ISO 45001) at our headquarters in Cesena, Italy. This stable foundation is supported by our dedicated long-term service structure, providing 24/5 remote support and rapid spare parts availability from a massive inventory of over 11,000 stock items to protect your manufacturing continuity.