650 Ton Self-Aligning Roller Beds: A Benchmark in Offshore Industry Engineering

Over the past 18 years of our active participation in the Wind Industry, the development of our 650 Ton Self-Aligning Roller Beds has become a true reference in this sector, particularly in the Offshore Industry.

This equipment represents the culmination of structural, mechanical and advanced automation engineering, designed to meet increasingly demanding production environments and to handle large-scale components such as monopiles and transition sections — 12 metres in diameter, 105 metres in length and 3,000 tonnes in weight.

We are currently developing the 4th generation of this system, featuring significant advancements in load capacity, operational performance and reliability. The next range includes units with capacities between 1,500 Ton and 2,000 Ton per roller bed, reinforcing our position as a global supplier of large-scale heavy-handling solutions.

Why are these roller beds different?

Advanced validation without full-scale physical testing Handling structures weighing hundreds of tonnes makes traditional factory acceptance testing (FAT) impractical. Therefore, we rely on advanced computational simulations, finite element modelling and dynamic behaviour analysis, ensuring reliability from the very first operational cycle at the customer’s site.

High-performance materials and components We select materials and components certified and specified to meet the extreme demands of this industry:

• high-strength and high-toughness structural steels;
• high-density technical polyurethane wheels;
• highly customised hydraulic systems;
• ultra-high torque drives (approximately 100 times more powerful than the first roller bed model).

This combination ensures robustness, durability and consistent operation throughout the entire service life.

Full integration in an automated factory Each roller bed communicates with the rest of the system via an industrial wireless network, enabling:

• automatic synchronisation between all roller beds and SAW welding gantries;
• continuous monitoring of load and relative position;
• centralised parameter configuration;
• integration with MES systems.

The result is a highly efficient production line with reduced setup times and complete process control.

Designed for XXL Monopiles

The system’s engineering was complemented by extensive studies on real monopiles, analysing deformations, critical support points and load distribution. This allows for an optimal configuration of the number of roller beds, ensuring homogeneous weight distribution, reducing stress and mitigating operational risks.

Intelligent hydraulic system

Each unit incorporates an automatic hydraulic adjustment system capable of:

• compensating for conicity and dimensional variations;
• raising and lowering the component to allow SPMT entry and exit;
• equalising the load among multiple roller beds, ensuring each unit operates safely within its limits.

This level of control transforms the roller bed into equipment that goes beyond simple rotation — it becomes a high-precision heavy-handling system. Would you like to know more about this product? Contact us now! Visit our website and discover our full range of solutions for the Renewable Energy Industry.