Coating repair at the Global Tech I offshore wind farm

Offshore wind farms operate in some of the harshest environmental conditions for steel structures: saltwater, constant humidity, wind, and mechanical stress permanently attack the protective coatings of the foundation structures. If damage is left untreated, corrosion threatens the load-bearing components.

‍

The challenge: keeping 80 geographically dispersed foundation sites in good coating condition long-term. This is demanding under offshore conditions for several reasons:

• Coating damage to the primary steel often occurs in hard-to-reach areas—even on ladders and platforms, damage is sometimes only accessible with significant effort.
• The extremely harsh, saline environment promotes corrosion and places high demands on the coating system.
• Coating may only be applied under permissible climatic conditions according to ISO 12944 (relative humidity, dew point, temperature)—which severely limits working hours.
• The multi-layer coating structure leads to additional waiting times due to drying periods.
• Work steps, damage, and repair sites must be clearly located and documented without gaps.

We addressed this task with a systematic, annually recurring maintenance approach. Six components form the backbone of the work:

‍

01 · Close coordination with the client

Early and detailed coordination—especially regarding logistics and campaign planning—ensures that personnel, materials, and site access are optimally aligned.

‍

02 · Annual maintenance campaigns

Recurring, predictable campaigns ensure that the coating is continuously maintained, keeping the overall condition of the structures at a consistently high level.

‍

03 · Use of industrial climbers

Hard-to-reach areas on primary steel, ladders, and platforms are accessed safely and efficiently by rope-access-trained personnel—eliminating the need for complex scaffolding or lifting equipment.

‍

04 · Continuous monitoring of climatic conditions

Relative humidity, dew point, and temperature are continuously monitored and recorded. Coating is only performed within the conditions permitted by ISO 12944, ensuring quality and providing verifiable results.

‍

05 · Optimized coating measures for spot repair

For localized repairs, we use a surface-tolerant, single-layer repair coating system that is highly resistant to changing environmental conditions. Targeted, optimized cleaning steps reduce salt contamination and remove dust and grease. A three-person team executes the systematic workflow of damage documentation, surface preparation, and coating application in designated areas.

‍

06 · Digital coating logs

Damage and repair sites are located and photographed in digital coating logs. This creates a seamless, clearly traceable record across all campaigns.

• 80 spatially distributed tripods, coordinated and maintained as a single portfolio.
• Long-term, continuous coating maintenance instead of isolated, one-off measures.
• Ongoing optimization of processes, work steps, and coating materials from one campaign to the next.
• Excellent collaboration with the client, which contributes significantly to the optimization of the work.

Continuous maintenance of the coating—carried out through annual campaigns over more than ten years—keeps the foundation structures in excellent condition for the long term.

‍

Through close coordination with the client and the continuous optimization of processes, workflows, and coating materials, both efficiency and quality are further improved with every campaign.