While the Creation remains a mystery the genesis of the very first Monopile XXXL plant of Japan it is the result of JFE vision and determination to create a unique installation.
The new factory in Kasaoka, had started with permissions and approvals on July 2021 and it represents for JFE the first new facility in approximately 50 years since. Building upon this foundation, JFE has incorporated cutting-edge equipment with a proven track record of monopile manufacturing.
Special wider and heavier steel plates, such as J-TerraPlate™, were selected for the Monopile production to reduce the cost of welding and to mitigate the emissions of the process and the latest updated engineering have been developed to the final design of the Monopile.
The technical proposal of the joint partnership FACCIN-OKAYA has been awarded for the supply among all of the World producers of Plate Bending.
Any process of this Monopile production has been developed especially to the JFE design and production schedule and to meet the requirement Faccin has accomplished the development of two identical bending lines each one consisting in a complex machine for handling and conveying the huge plates and a FACCIN GIGAROLL 4 roll plate Bending 4R 4200X150 equipped with ancillary systems such as smart multifunction side supports and vertical supports to assist the rolling operations of cones and cylinders. The two Faccin GIGAROLLS are the heart of the Monopile production to bend plates to manufacture cones and cylinders up to 12.000mm diameter (with the machine model ready for upgrades to 15.000mm) and 130mm plate thickness.
The handling and conveying machines are designed to adjust and conveying the plates exceeding 40 mt length and 4200mm width.
FACCIN GIGAROLLS N.1 AND N.2 with Heavy-Duty Side Supports and Vertical Support
The FACCIN latest design, specifically developed for JFE, has the plate always supported on rollers for both longitudinal and transverse axis to eliminate any friction on the plate surface.
Plates with prepared side bevel can be adjusted without any damage to the weld preparation.
A constant monitoring on the position of plate in respect to the plate bending rolls is constantly displayed in the operator panel and subroutines for automatic plate displacement can be activated to progressively roll cones up to 12000mm diameter and 130mm plate thickness.
The handling and conveying machines can switch from cylinder to cone production from the operator panel.
The operator has all the installation view from his site thanks to cameras displayed on a separate panel.
The Handling and conveying machines can be operated in parallel with the plate bending and also independently to reduce the production cycle times.
Automatic measurement to improve the automation and to speed up the inspection process. Faccin has installed in both machine the latest EYE BEND a laser measuring platform that furnish in real time the bending radius.
The GIGAROLLS hydraulic system and main drive with Modular design to share the same components and to facilitate the spare parts management.
All hydraulic axis are proportionally controlled assembled on a compensated manifold with Load Sensing control.
The main top roll drive is the most reliable in terms of durability torque delivery and rotation smoothness.
A primary custom gearbox with central gear and four satellites hydromotors with epicyclic reduction unit.
Faccin Group has already 51 years of experience in this design in heavy duty application.
Such incredible new XXXL plant required a very strict planning following the approved construction schedule.
Faccin met the schedule and on March 19th 2024, the inauguration for completion took place with the presence of JFE PRESIDENT and CEO Kazuyoshi Fukuda. FACCIN GIGAROLL started the first rolling demonstration and on April 1st it has started the production for the monopile.
The FACCIN GIGAROLLS are set to produce initially 100.000 Ton of plates per year contributing to support 400 new employee activity.
For more information www.faccingroup.com
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