The evolution of the Coastal Virginia Offshore Wind (CVOW) project represents a significant milestone for the US energy sector and a major achievement for the EEW Group. Through the immense scale of XL monopile production, EEW demonstrated the logistical resilience required to overcome global disruptions and ultimately support the energy transition.
2020: Breaking Ground in US Federal Waters
In April 2020, EEW Special Pipe Constructions GmbH announced the successful fabrication of two heavy monopile foundations and transition pieces for the CVOW demonstration project.
These structures, which weighed 877 metric tons each and featured a diameter of 7.8 meters, were the first monopile foundations ever installed in US Federal waters. This pilot phase was of profound importance as it was the first project to pass all phases of BOEM approval, effectively paving the way for the large-scale commercial industry that followed.
2022–2025: Massive Commercial Manufacture
Following the successful delivery for the demonstration project, Dominion Energy awarded EEW SPC the contract for the full-scale commercial project in September 2022. By supplying the first offshore wind farm of this scale under construction, EEW Group has solidified its role as a pioneering leader in the emerging American market.
The largest wind farm in Europe to date, Hornsea 1&2, is already standing on our monopiles. Now we are pleased to announce that the largest wind farm in the USA is also being built with our foundations. With the construction of Coastal Virginia Offshore Wind, Dominion Energy is getting closer to its self-imposed goal of carbon neutral power generation by 2050 and we are pleased that we can also do our part, said Michael Hof CSO of EEW Group.
This new phase required the production of 176 XL monopiles, a task involving the processing of more than 200,000 tons of steel. The engineering requirements grew significantly compared to the pilot stage, with monopiles reaching diameters of up to 9.5 meters, lengths of 83 meters, and individual weights of up to 1,538 tons.
Overcoming Complexities: Engineering & Logistics
The logistical execution of this project required precision and resilience. Production started in May 2023, and over the course of two years, the EEW Group managed a complex transatlantic supply chain consisting of 27 separate shipments.
Despite global disruptions such as COVID-19, the war in Ukraine, and adverse weather conditions that impacted the supply of materials, EEW maintained a schedule so efficient that no vessel was ever left waiting for its cargo. To achieve this, a specialized fleet transported the piles, with the average round trip from Rostock to Virginia taking 51 days.
The technical complexity of the loading process was equally demanding. A high degree of precision was required to slide pipes into one another to a depth of more than 13 meters to optimize transport space. Using the Gantry System and 90 SPMT axles, the monopiles were moved in separate convoys and jacked at the quay for placement onto transport cradles. Precise positioning of the cradles was essential to safely secure the cargo, which typically weighed between 6,600 and 8,000 tons per journey.
The final shipment was completed in August 2025, signaling the successful delivery of all 176 monopiles. Once construction is fully complete in 2026, the Coastal Virginia Offshore Wind farm will stand as the largest in the United States, providing renewable electricity to approximately 660,000 households.
We value the excellent collaboration with EEW SPC on this project. The monopiles they have supplied are of the highest quality, and we have complete confidence in our experienced partners throughout the entire process, said Karl Humberson, General Manager Offshore Wind at Dominion Energy.
