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Sustainable largescale manufacturing of offshore wind

Abstract

The Challenge The European Commission estimates that up to 450 GW offshore wind is needed by 2050; North Sea countries have committed to an ambition of 300 GW by mid-century; Norway aims for seabed allocations corresponding to 30 GW by 2040. With current turbine sizes, meeting European targets requires manufacturing, transporting, installing and connecting more than 1,000 turbines per year for 25 consecutive years. The gap between ambition and current reality is significant. Costs remain high — particularly for floating wind — and supply chains are fragmented. Project delivery still relies on bespoke engineering and one-off logistics rather than repeatable, standardised processes. A structured approach towards standardised serial production of offshore wind is required to become cost-competitive. The challenge is no longer whether offshore wind can be built, but whether it can be built at the scale, speed and cost required. The Value Chain and Norway’s Position The offshore wind value chain is tightly connected and spans design, manufacturing and fabrication, transport and installation, operations and maintenance, and decommissioning. Cost and risk are determined not only by individual components but by how well the full value chain works together. Norwegian industry generated NOK 60 billion in offshore wind revenue in 2024, but this is dominated by maritime services; fabrication of foundations and floating substructures represents only a small share today. Norwegian industry has recognised strengths in floating structure design, subsea technology, mooring, cables and offshore operations — all transferable to offshore wind and representing clear growth opportunities as deployment scales. Three Levers for Cost Reduction Cost reduction is driven by three primary levers that must be applied in coordination across all parts of the value chain: • R&D and innovation. Technology development, design evolution and knowledge generation. Innovation lowers cost by improving technical performance and making components suitable for industrial production, but only when compatible with available manufacturing capacity and supply-chain conditions. • Upscaling of capacity. Expansion of manufacturing, logistics and installation capabilities. Upscaling reduces cost through learning effects, higher utilisation and spreading of fixed costs across larger production runs — but requires mature, repeatable solutions and predictable long-term demand. Two Overarching Conclusions Two conclusions cut across all segments. First Cost reduction requires coordinated use of all three levers. R&D delivers results only when new solutions are compatible with manufacturing capacity and supply chains. Upscaling requires mature, repeatable designs. Standardisation enables both but must preserve room for innovation. There is no shortcut through any single lever alone. Second Large cost-reduction opportunities lie at the interfaces between value chain segments, not only within individual segments. Turbine–substructure interfaces, fragmented vessel strategies, late design changes and incompatible data systems are highcost problems — and they are invisible when each segment is optimised in isolation. An end-to-end value chain perspective is the prerequisite for finding and acting on them.

Category

Research report

Language

English

Author(s)

Affiliation

  • SINTEF Industry / Metal Production and Processing
  • SINTEF Industry / Materials and Nanotechnology
  • SINTEF Industry / SINTEF Manufacturing
  • SINTEF Digital / Mathematics and Cybernetics
  • SINTEF Energy Research / Energy Technology
  • SINTEF Energy Research / Energy Systems
  • SINTEF Energy Research / Renewable Energy
  • SINTEF Ocean / Energi og transport
  • SINTEF Ocean / Skip og havkonstruksjoner
  • Norwegian University of Science and Technology

Year

2026

Publisher

Norwegian University of Science and Technology (NTNU)

View this publication at Norwegian Research Information Repository