GS Entec has transformed its facility from producing petrochemical equipment to a cutting-edge manufacturing base for large offshore wind structures.
During a visit to the GS Entec Yongjam Factory in Ulsan on October 26, a massive machine was seen rolling long steel plates into cylindrical shapes. The diameter of the test cylinder being produced that day was 9.6 meters, with a thickness of 75 mm, drawing gasps of admiration for its size. A yellow 'gripper' capable of lifting up to 100 tons was used to move these cylinders. When welded together, these cylinders will form monopiles that support wind turbines underwater.
Until just two years ago, the Yongjam Factory was focused on producing petrochemical equipment. However, with GS Group identifying offshore wind as a new growth engine, the factory has undergone significant changes. As the only monopile manufacturer in South Korea, GS Entec invested 300 billion won to establish dedicated automated production equipment, increasing its annual monopile production capacity from 40,000 tons to 150,000 tons, a 3.75-fold increase. The company emphasized the need for government support for a backport to store and transport large equipment as it expands its domestic and international orders.
On the same day, GS Entec held a ceremony to inaugurate its dedicated automated production equipment for monopiles at the Yongjam Factory. The event was attended by GS Group Chairman Huh Tae-soo, Vice Chairman Hong Soon-ki, GS Entec CEO Huh Cheol-hong, and Kun Boo-has, CEO of Dutch monopile specialist Sif.
Monopiles are large cylindrical structures made from steel plates that support the towers and turbines of offshore wind farms. As wind turbines have grown larger, monopiles have also become heavier and bigger. The Yongjam Factory can produce monopiles with a maximum diameter of 11 meters, a length of 100 meters, and a weight of 2,500 tons.
The production process at the factory includes welding steel plates together, processing, shaping, and welding. The long steel plates are moved along a conveyor to a bending machine, where they are rolled into shape. The joints are then welded to create the cylindrical components, which are further connected to form the monopile.
Welding the thick steel plates without gaps is crucial. A factory representative explained that the plates are preheated to about 100 degrees Celsius before welding to prevent defects. The welding process involves working both inside and outside the cylinder, with workers using elevators to reach specialized platforms for high-altitude tasks.
This production system was established through technological collaboration with Sif, with which GS Entec formed a strategic partnership in 2023. The company integrated its existing expertise in large steel plate processing and welding with the specialized equipment and operational experience for monopiles.
Looking ahead, GS Entec has identified logistics infrastructure outside the factory as a key challenge. Due to the size and weight of offshore wind equipment, there are limited docks available for storage and handling. Installation schedules can vary based on offshore weather conditions, necessitating a rapid supply chain for products that are pre-manufactured and stored until they can be deployed.
Song Won-gil, GS Entec's Chief Strategy and Executive Officer, reiterated the urgent need for a backport during a press conference. He stated that to maximize the use of domestic production facilities and enhance competitiveness, supporting infrastructure is essential.
While the absence of a dedicated backport does not immediately disrupt production, GS Entec noted that it can utilize existing docks at Ulsan Port. However, the company faces the burden of securing separate docks for storage and transportation for each project, and with anticipated increases in offshore wind orders, a dedicated facility is necessary. Song emphasized, "Infrastructure such as backports must be expanded to meet the annual order volumes rather than just to avoid production delays."
GS Entec plans to target overseas markets, including Japan, based on its domestic supply record. The company completed the installation of 64 monopiles for the Yeonggwang Nakwol offshore wind project in June. In September, it signed a contract to supply 37 monopiles for the 504 MW Taean offshore wind project, with production set to begin in July 2027 and deliveries scheduled through August 2028.
The company aims to secure additional orders for 2-3 domestic projects and 1-2 projects in Japan. GS Entec plans to pursue contracts based on its production capacity, focusing on projects expected to emerge between mid-2028 and 2030.
Huh Cheol-hong stated, "By combining Sif's technology with GS Entec's manufacturing capabilities, we aim to enhance quality and delivery competitiveness, and expand our presence in the global offshore wind market based on our domestic business achievements."
* This article has been translated by AI.
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