Project overview
Built between 2022 and 2025, SeAH Wind Monopile Factory marks a significant milestone, not only as the first major development on Teesworks, but also as a critical component in the UK’s ambitious plan to fully decarbonise electricity generation by 2035. Teesworks is one of Europe’s largest regeneration zones in northeast England.
A monopile is a large steel tube placed into the seabed to support offshore wind turbines, especially in shallow waters. It’s strong, cost-effective, and easy to install, providing a stable base to keep the structure upright. Spanning 800 metres and offering 1,130,000 ft² of factory space, SeAh’s facility can produce 100 to 150 monopiles per year, each up to 120 metres long and weighing as much as 3,000 tonnes. Now fully operational, the factory plays a key role in helping the UK quadruple offshore wind capacity from 15GW to 60GW by 2031.
Objectives
Omega Red was appointed by a leading mechanical and electrical (M&E) partner in the UK on behalf of SeAh Wind Ltd to design and install lightning protection and electrical earthing systems for the factory, to meet the following objectives:
- Prevent structural damage and protect electrical systems
Design and install a reliable system to mitigate the risks of lightning strikes and electrical faults, ensuring the integrity of the building and its infrastructure. - Ensure occupant safety
Provide effective protection for all building users by reducing the risk of injury or harm caused by electrical surges or lightning-related incidents. - Achieve full compliance with industry standards
Meet all relevant regulatory requirements, including BS EN 62305 (Lightning Protection) and BS 7430 (Earthing), to ensure long-term safety and legal compliance.
Scope of works
To meet the complex demands of the project, Omega worked collaboratively with a wide range of stakeholders, including specialist drilling subcontractors. This approach was essential in adhering to a strict and fast-paced program of works. Our teams operated on a 24-hour continuous work cycle, demonstrating exceptional coordination and commitment. Multiple dedicated delivery teams were involved, each supported by experienced project managers and guided by robust safety, health, environment and quality (SHEQ) protocols to ensure compliance and performance at every stage.
In addition to our onsite operations, a comprehensive back-office function was established to maintain quality and technical oversight. This involved Omega providing a bespoke earthing design solution to suit project specific characteristics, alongside the development and management of inspection test plans (ITPs) and quality assurance processes. By implementing these systems, we ensured that all relevant technical data was accurately recorded and validated throughout the installation process, ensuring full traceability and compliance with project specifications.
Challenges
Despite the successful delivery of the project, several challenges had to be carefully managed to maintain progress and quality.
One of the most significant challenges was the accelerated delivery schedule, requiring continuous 24-hour operations. This demanded precise coordination across multiple teams and disciplines, with no margin for delay.
Omega deployed multiple delivery teams working in shifts, supported by a robust project management structure. This ensured continuous progress without compromising safety or quality.
Outcomes
The successful delivery of Lightning Protection and Electrical Earthing systems by Omega Red resulted in several key outcomes aligned with the project’s original objectives:
- On-time, on-budget delivery
Despite the demanding 24-hour work schedule and tight program, the project was completed within the allocated timeframe and budget. This was achieved through proactive planning, disciplined execution, and strong stakeholder collaboration. - Full compliance with industry standards
All installations met or exceeded relevant compliance regulations, including BS EN 62305 for lightning protection and BS 7430 for earthing. Robust ITPs and quality control processes ensured that regulatory and technical standards were upheld at every stage. - Enhanced safety and protection
The completed systems provide comprehensive protection for the building, its infrastructure, and its occupants from electrical surges and lightning strikes. This enhances long-term operational safety and business continuity. - Operational efficiency and cost control
The integration of quality assurance processes and efficient delivery methods helped avoid costly delays or rework, contributing to overall cost savings for the client. - Minimal disruption to site operations
The 24-hour rolling schedule and phased approach to delivery allowed for minimal disruption to concurrent construction or operational activities on site.
