A world-leading shipbuilder diversifies into renewable energy using its skills and ArcelorMittal steel
Chantiers de l’Atlantique is best known for building some of the world’s largest cruise ships. Around a decade ago, the company decided to diversify and began building substations for offshore wind farms. At first glance it might seem that ships and substations have little in common, but the reality is that both require exceptional planning, detailed knowledge, and the ability to turn tonnes of ArcelorMittal steel into vast structures which can withstand the harsh environment of the open ocean. The latest substation to be built by Chantiers de l’Atlantique was installed in August 2021 and will service the Saint-Nazaire offshore windfarm. The windfarm is operated by EDF, France’s largest energy provider, and will progressively generate energy from the middle of 2022. This will be the fourth Chantiers de l’Atlantique substation for which ArcelorMittal has provided steel.
“In terms of project management and the integration of equipment, there are many similarities when it comes to building ships and substations,” notes Yann Penduff, Project Manager for Chantiers de l’Atlantique. “For example, we use the same modular approach to construction and many of the same technologies for both applications.”
“Power transformation and distribution, which are also the main functions of a substation, are an integral part of shipbuilding,” explains Yann Penduff.
The substations are built from both normalised and thermo-mechanical grades from ArcelorMittal Europe – Flat Products. “The steel has specific chemical and mechanical properties,” says Serge Hily. “It also exhibits excellent welding properties.”
ArcelorMittal delivers plates for both ships and substations every two weeks by sea from its mill in Gijon (Spain). “We can adjust the volumes as required,” explains Serge Hily, Steel Purchasing Manager for Chantiers de l’Atlantique. “If more steel is needed urgently, the mill is close enough to allow deliveries by road.”
To facilitate quick communication, ArcelorMittal deployed a technical engineer and an R&D specialist to the Chantiers de l’Atlantique. “The presence of the ArcelorMittal personnel enabled us to get fast responses to technical questions,” says Serge Hily. “It really accelerated the dialogue between the technical teams. This was critical given the small time-window available.”
The mammoth substation structures made for EDF Renewables are 20 metres high, 20 metres long, and 30 metres wide. Each one weighs around 2,200 tonnes
Chantiers de l’Atlantique paints or treats every piece of steel in the substation to withstand the corrosive offshore environment. “ArcelorMittal R&D has developed many innovative corrosion resistance solutions for use in marine environments,” notes Laurent Castro, ArcelorMittal account manager for Chantiers de l’Atlantique. “This work continues in cooperation with customers such as Chantiers de l’Atlantique.”
Once it is painted, the substation is fitted out with the technology needed to transform energy from the windfarm and transfer it to shore.
One of the biggest challenges Chantiers de l’Atlantique faces when building substations is the tight deadlines. “There are very few vessels available to install substations at sea,” notes Yann Penduff. “We must book the vessel three years in advance, and then we have just one week to install the substation on its foundation. That requires clockwork precision from our team and our suppliers.”
A specialised ship lifts the substation place onto a jacket or monopile which has already been installed.
The Saint-Nazaire substation was installed in August 2021. When it is fully operational in April 2022 the substation will transmit to shore around 480 megawatts of electricity, produced by 80 turbines. The windfarm will generate around 20 percent of the energy consumed by France’s Loire-Atlantique department which is home to over 1.4 million people.
ArcelorMittal’s offer for wind energy and shipbuilding
ArcelorMittal Europe – Flat Products can supply offshore and shipbuilding grades with very high strength and toughness. Plates are available in widths up to 3.3 metres with a tensile strength of up to 460 Mpa. The maximum weight of a single plate can be up to 19 tonnes. ArcelorMittal is actively working to increase the thickness range of our plates for wind energy and shipbuilding. The dimensional feasibility of ArcelorMittal’s offer reduces the number of welds required, reducing costs and production time significantly.
Like all ArcelorMittal steels, our offer for wind energy and shipbuilding is available with XCarb® green steel certificates which enable customers to reduce their Scope 3 emissions. ArcelorMittal’s XCarb® initiative brings together all of our reduced, low and zero-carbon products and steelmaking activities, as well as wider initiatives and green innovation projects, into a single effort focused on achieving demonstrable progress towards carbon neutral steel.
More info on ArcelorMittal’s offer for wind towers: industry.arcelormittal.com/windtowers
More info on ArcelorMittal’s offer for shipbuilding: industry.arcelormittal.com/shipbuilding
More info on XCarb®: corporate.arcelormittal.com/climate-action/xcarb
Pictured at the 2019 Suppliers of the Year ceremony are (from left to right) Bertrand Paquet, Purchasing Director Chantiers de l’Atlantique ; Laurent Castaing, Chantiers de l’Atlantique’s CEO; Laurent Castro, key account manager for ArcelorMittal and Serge Hily, Sourcing Department Manager at Chantiers de l’Atlantique.
All images are © Chantiers de l’Atlantique