Streamlining Pin Piles Logistics

Abstract

As offshore wind turbines grow beyond 15 MW, the logistical and mechanical challenges of installing large-diameter pin piles have intensified. Conventional upending methods, such as crawler crane-based operations, face increasing limitations in deck space efficiency, motion sensitivity, and operational persistency, thereby constraining the scalability of current offshore foundation installation practices. This study presents an integrated framework to identify and evaluate next-generation logistical concepts for pin pile handling. Through a structured morphological approach, over 120 storage, transport, and upending configurations were generated and screened through a Multi-Criteria Analysis (MCA). The top-performing concepts were further analyzed using Multi Operation Persistency (MOP) simulations to quantify weather downtime and operational duration. Cost modeling revealed that concepts combining in-grillage storage with tail-end rotation mechanisms significantly reduce project duration and total project costs compared to the baseline. Following from this, two refined mechanical solutions, Deck Rotation and Dutch Bike Rack, were developed, optimized for lifting height, and validated for structural and dynamic feasibility. Both mechanisms enable safe, reversible upending within compact vessel layouts. The results demonstrate that logistical integration and mechanical innovation can unlock new efficiencies in offshore wind foundation installation, offering scalable and cost-effective solutions for future energy infrastructure.