Seafaring is one of the world’s oldest occupations. With a history that dates back as far as the Egyptians and the Vikings, life at sea has long been crucial for exploration and trade.
But after hundreds of thousands of years, the appeal of a life at sea is dwindling, particularly in the U.K., with industry recruiters sharing that the number of applicants entering maritime training programs has significantly declined, especially since the COVID-19 pandemic.
The U.K.’s maritime sector is now turning more to foreign labor to crew its vessels, drawing offshore teams from countries such as Poland, Latvia, and Romania.
Aware of the challenge at hand, offshore infrastructure vessel and support services company, North Star, has taken proactive measures to retain and develop its workforce as well as attract additional talent.
Having already transitioned from the fishing industry to oil and gas, and now in its latest evolution — renewables — the 138-year-old business is striving to remain competitive in the marketplace.
The firm, which boasts the U.K.’s largest wholly owned fleet, looks after all its ship management in-house. Its combined shoreside crewing department of 19 oversees all placement, travel, and development for its seafarers, building a strong and supportive inclusive culture.
The Grampian Tweed is one of four SOVs in North Star’s fleet. (Courtesy: North Star)
Evolving approach
As North Star accelerates its shift into the offshore wind sector, its approach to crewing up is evolving to match the pace of change. The company’s new generation of Service Operations Vessels (SOVs) marks a major milestone, not only in fleet capability but also in how crews are selected, trained, and supported.
Recognizing that skilled, experienced seafarers are essential to safe and efficient operations in offshore wind, North Star is strategically redeploying talent from its emergency response and rescue vessels (ERRVs), many of whom possess transferrable skills well-suited to SOV roles.
Resources that include providing industry-leading crew welfare initiatives, such as onboard gym equipment and improved communication systems, help to ensure job satisfaction and long-term retention amongst its 1,300 seafarers, who are all employees rather than contracted personnel, operating in the North Sea. With bases in Aberdeen, Lowestoft, Newcastle, and Hamburg, North Star’s fleet boasts 44 assets. The company provides safety-critical, continuous, around-the-clock support services to more than 50 North Sea installations with its ERRVs. It has four SOVs — the Grampian Tyne, Grampian Derwent, Grampian Tees, and Grampian Tweed — delivered to the Dogger Bank Wind Farm partners, for 10-year minimum charters. In addition to this, the business has four newbuilds underway, which will support offshore wind projects in the U.K. and across Europe.
The North Star SOV fleet. (Courtesy: North Star)
Providing opportunities
At the heart of its recruit-and-retain strategy is providing opportunities for its talent to grow. But with less people applying for jobs at sea and an aging workforce working on vessels today, there is a real urgency to cultivate a new generation of crew. Putting succession plans in place with a focus on transferring knowledge and skills is crucial for maintaining the industry workforce.
North Star has developed a strategic approach to crewing its vessels. It has found, over the years, that to help preserve the company’s culture and high operational standards, it is vitally important to retain crew that external and incoming talent can learn from and then apply this to the burgeoning offshore wind market. At North Star, about 50 to 60 percent of new positions on the recently built SOVs have been filled by personnel already within the company. This allows the company to not only give current employees an opportunity to develop in their own careers, and experience this next generation of seafaring as we transition into offshore wind, but also nurture the fresh talent coming through the doors and working alongside them.
Much of this transfer has come from the many crew members who have previously worked on North Star’s fleet of ERRVs, and who therefore possess the skills that are transferable to SOV operations.
Ratings provide an excellent route into seafaring careers. (Courtesy: North Star)
Training programs
With some additional training and certification required for coxswains, progressing ERRV crew members from OPITO to Royal Yachting Association (RYA) qualifications, North Star has invested in training programs to facilitate this type of smooth transition. This has included working with training providers such as RYA Sail and Powerboat in Lowestoft and You and Sea in Helensburgh.
North Star is also collaborating with training providers and nautical colleges across the U.K. and Europe, to enhance skills for dynamic positioning, crane operators, and walk-to-work gangway operators, areas where there is currently a skills shortage.
An important but often overlooked route into seafaring careers is through ratings. Performing essential tasks in both the deck and engine departments, ratings gain hands-on experience under the supervision of senior officers. By offering structured career progression and skill development, vessel operators can enhance the appeal of this role, making them a more attractive entry point into the maritime industry.
This type of training initiative not only helps recruit aspiring seafarers but also ensures a steady supply of skilled personnel ready to move up the ranks. North Star had a really positive experience with this, partnering with North East Scotland College (NESCol) in Peterhead to recruit from their Efficient Deckhand (EDH) courses to backfill positions on ERRV of those who have transitioned to SOV roles. This program introduces individuals to the industry, allowing them to start as trainee ratings before progressing to deckhand and ultimately coxswain positions, ensuring a structured career development path.
Skilled, experienced seafarers are essential to safe and efficient operations. (Courtesy: North Star)
Finding and retaining new talent
Attracting new talent is the final challenge to building crews. As the industry continues to scale up to meet global climate goals, a new generation of skilled, motivated professionals is needed to drive innovation, maintain high safety standards, and support the rapid deployment of renewable energy infrastructure.
With an aging maritime workforce and fewer young people pursuing seafaring careers, bridging this talent gap is more urgent than ever.
However, certain perceptions and lack of visibility of the sector can affect this. Low diversity, poor conditions in certain occupations, and the lack of career progression are slowing the talent pipeline. Even those in traditional maritime towns are beginning to seek other careers.
A Maritime U.K. poll [1] found nearly half of 18- to 24-year-olds near the coast planned to move away due to job scarcity, but 70 percent would stay if the right opportunities existed.
This is why maritime educational opportunities should be created for young people — engaging with them early and providing hands-on experiences, to spark interest and enthusiasm for marine careers. Additionally, many young people are unaware of the opportunities that exist across the maritime sector. Seafaring can lend itself to a whole host of careers at sea including offshore support vessels, ferries, cruise ships, and yachts.
The introduction of SOVs at North Star has sparked renewed interest, seeing a reverse in decline in cadet applications. With offshore wind projects on people’s doorsteps, like Dogger Bank, enthusiasm is growing, and North Star must step up and showcase the breadth of work that the sector offers. From engineering and vessel operations to data analysis and environmental monitoring, the sector offers dynamic career paths with real-world impact.
North Star aims to expand its outreach, with new cadet intakes planned for September 2025 at multiple U.K. maritime colleges including Glasgow and South Shields. As the country’s largest employer of offshore cadets, over the last two decades it has trained hundreds of future deck and engineering trainees, investing 1 million pounds annually on average to develop the next generation.
Its investment in training, welfare, and career development not only support the company’s expansion into renewables but also help future-proof the industry as it adapts to emerging challenges and opportunities.
References
Maritime U.K. poll “State of the Maritime Nation 2022: https://www.maritimelondon.com/wp-content/uploads/2022/06/CEBR-report-2022pdf.pdf.
Lilholm: Within the DNV supply chain and product assurance division, I’m the global head of sustainability and ESG services. My role is about accelerating responsible and credible decarbonization across hard-to-abate sectors as well as sectors where DNV has a strong presence, including wind energy. I’m based in Copenhagen, but we have a global focus.
Zeitzen: I’m based in Copenhagen, and I have the Nordic focus. We have a team of sustainability specialists within supply chain and product assurance and focus our clients with a couple of key questions. One of them is: How can you prove that something is green – or better: environmentally and socially sustainable? This is related to green claims and trust in the market. DNV provides trust, and one of the trust elements is: Do you have proof of what you are saying? Is something green/sustainable, does your claim live up to the standards, to best practices?
And secondly, of course, in terms of the wind industry, if something is doing good, is it also made well? For example: If you make a wind turbine that is producing renewable energy, you don’t want to have the reputational issue that the copper you’re using has been sourced from a mine, which is environmentally unsustainable or violates workers’ rights or is unable to control corruption.
What makes the environmental and social impact of the wind-turbine supply chain an important issue to tackle?
Zeitzen: To create energy, you need the space to put up the wind turbines. You have to prove that your turbines are technically performing to the standard in that certain location in the expected wind conditions. You need to showcase and prove technically it’s doing the trick, that it’s performing.
And you also have to look at it in terms of how it’s made. We see this increasingly, especially in Europe, where the legislators or the tendering bodies are asking for information or mitigation of social impact within their value chain. They’re asking for footprint; they’re asking for recyclability and circularity, biodiversity; they’re asking for information about the social impact of turbine production, during the construction phase and the operation phase. All aspects and questions that look beyond the technical performance.
If you look at one of the most sustainable companies in the world, Ørsted, which is a Danish utility company, they’re even going so far that when they put up a wind turbine and put in the concrete foundations, they put bubble curtains around the installation tolower the impact on biodiversity, on the sea life, around the installation site.
Lilholm: Wind energy is trying to do good. It’s part of the climate mitigation that goes toward renewable energy and energy transition. But in that process, what is defined as a part of the EU taxonomies or in other taxonomies globally is to do no significant harm. In other words, while you try to achieve one objective, you don’t compromise another one. You don’t need loss of biodiversity or violations of human rights or pollution or other concerns, and you don’t have material negative adverse impacts on other things while you try to achieve one good, positive outcome. That holistic view is key for the industry to demonstrate that they have full control.
Another consideration is the different frameworks in place depending on where you are installing and where you are supplying. At DNV, we are helping to manage all these performance metrics surrounding the product in terms of environmental performance, social performance — according to guidelines and principles and frameworks — and what is needed to be disclosed.
Wind turbine life cycle assestments have been around for 30 years. (Courtesy: DNV)
How can wind farms accelerate supply chain decarbonization through digital transformation and comprehensive life cycle assessment?
Zeitzen: Let’s start with the last part: life cycle assessment, the LCAs. They have been around for 30 years, and what they do is shed light on how much carbon you are emitting when you are producing and when you are transporting between the production site, from the mine or from the raw materials location down to the factory gate — or even to the installation gate. It gives you the insight, the transparency, about where you have the levers to work with your production in order to decarbonize.
How to do an LCA is described in ISO standards. If you look at the greenhouse gas protocol, which has been around for decades, on how to assess the emissions and how to assess impact, this is where the value counts for these companies — to shed light on the impact and where the impact is caused in the supply chain. Ask yourself, do my Tier One, Tier Two, and Tier Three suppliers have an LCA? Do they have a focus on their own processes? And then you can develop levers and see where the biggest impact or the biggest value is gained. Where should the focus be set to decarbonize? If you explore the decarbonization in turbines, then you can’t get around the question of steel.
Lilholm: Steel makes up a huge chunk of the wind turbine. Approximately 85 percent of material mass in the turbine tower is steel. Looking at the kind of product itself, designing the product, and also sourcing the material for the product in a more sustainable way is key.
Ultimately, the purpose of the energy transition is to lower the emissions per kilowatt, but you also need to look at the products. They should exhibit a lower emissions profile, and, therefore, the steel bought should be steel that is sustainably made.
When it comes to steel, even steel makers are now undergoing quite a bit of a transition toward becoming more sustainable and also becoming more responsible. DNV works with organizations like Responsible Steel. It defines 13 principles of responsible steelmaking — looking at ethics, social, health & safety, environmental, and so on. That’s on the steel making side.
But the steel supply itself also needs to be low carbon intensity, and there are different performance levels.
So, what defines a green steel? There is not yet one single definition of what green steel is, but there are definitions on some steel definitely being greener than others.
The ones buying the steel need to be able to navigate this, and they need to be able to understand it well enough so they can translate it into communicating their emissions resulting from their purchase. That’s where we can help a lot. We understand that the performance requirements when you recycle steel are different than when you take prime steel.
The reality is, to sustain urban growth for every need of the population and so forth, we can’t only rely on recycled steel, we are going to also need to rely on prime steel. There is a definition there. You also want to favor sustainable prime steel as well as sustainable scrap steel that goes into turbines.To make informed decisions, they can only do that by unpacking those definitions.
Zeitzen: It gets exciting here, because you buy a slab of steel, and you have no idea if you can trust how much the emissions were. So, you need to be able to trace this back to where, and how, it has been made. There are digital tools available that can trace aluminum through the supply chain, and it’s possible for steel, too.
You actually want to be able to trace it back and to transparently see and demonstrate to your buyers, to your stakeholders that, yes, we have done everything possible to document and to trace where the steel is coming from. Is this really including 30 percent scrap steel that is coming from the construction industry that has been used to make the steel slab? Yes! Now, you can prove it and this is what we are about. That’s what we live for.
Why are advanced turbine coatings important, and how can they make an impact on durability, erosion prevention, and long-term sustainability?
Zeitzen: With an anti-corrosion protection or with a corrosion-retarding solution, you’re trying to increase the lifetime of the asset and during this lifetime you have to maintain it. For a wind turbine on land, it’s easy. Any day of the week you can send a drone up and take a picture to see if there’s any corrosion.
For offshore wind installations, you don’t get to go there every day. So, we need to be sure that what has been put up — be it the concrete, the steel, the sleeve, the tower, the nacelle — that these steel elements are effectively protected against the impact of a harsh environment.
And then comes the coating. What the coatings are doing is helping to optimize the use of steel and then helping to optimize the maintenance intervals and potentially reduce maintenance cost. It’s about what the coating is made of and if it been proven that the coating has been successfully used in a harsh, marine environment.
You can deduce a lot from inspection data, performance data, and even from the oil industry where steel has been used on steel rigs — where coatings have been used to protect the steel construction. Can this knowledge be transferred into the wind-turbine world? Absolutely.
This is what we are doing with our engineers — looking at the structural effects of coatings and then looking at the tests, reviewing inspection data, and looking at scientific studies in order to find out if we can corroborate and support a case.
What measures can be taken in order to strengthen market credibility?
Lilholm: In our role as an independent accredited assurance company, we bring a lot of impartial expertise in assessing scientifically whether it’s corrosion or whether it’s a claim around low carbon intensity or if this steel was recycled. All those claims need a level of confidence linked to the evidence. Someone needs to understand what evidence you need and how you measure it with the confidence levels required. That’s exactly what we can do at DNV. We provide that assurance; we provide that credibility as a third party.
Companies are increasingly trying to become more credible and transparent about their sustainability performance, but they don’t always have the data — but they start from something, and then they become better and better at it. We talked before about life cycle assessment, and we talked about suppliers’ environmental profile. Not every data point is available upfront, but the idea is to begin the journey and then build more and more depth and detail into it as you advance your decarbonization data.
What is circular manufacturing and how is it being applied to the wind industry?
Lilholm: Circular manufacturing is about product design, product innovation, and business model innovation. An example of such would be: How can you enable your suppliers to base their supply on something of circular origin and how can you define your product design and material strategy in such way that what you supply is also more recyclable — so that what you are buying and supplying ultimately is part of a circular economic model or a circular value chain?
A common myth around circularity is that a single actor really can accommodate the entire circular activity, but this is not the reality. Instead, there needs to be a collaboration between players to reduce adverse impacts and extend the use and longevity of materials. Making product design more standardized also helps the repairability and serviceability of the systems, making the access to training on maintenance more scalable and the access to spare parts more widely accessible.
Digital transformation is an example that is going to support and likely accelerate it. We see in Europe the so-called digital product passport, commonly referred to as DPP. This is a connected products platform, performing as an electronic data carrier of valuable product information through its value chain, with the purpose of enabling circular economic behavior. For instance, what it is made from, how to best recycle a product, and how to make a claim about the end-of-life of that product. All these data points will optimize that circular efficiency.
Zeitzen: If we look back at the U.S. way of dealing with used blades, you’ve probably seen the pictures and been at landfill sites where they dig a hole, put a blade in, and put sand over it, and hope that the site isn’t reused. You don’t want to be connected to a landfill at the end of it. And then, in the European theater, you’re not allowed to landfill used blades anymore. There’s a lot of focus on downcycling and on recycling.
Our customers, who are leaders in the industry, are now looking at how to recycle blades chemically or biologically, asking themselves: How can I break them down with any sort of physical matters and reshape the materials for, let’s say, the building industry as building materials. We have houses made out of ground-down wind-turbine blade waste. The golden solution here, of course, is: Can I unpack the composite materials in blades, and can I reuse it to make blades again? Then, you get to full circularity.
How is DNV helping organizations ensure they are properly addressing these ESG compliance, supply chain integrity with performance optimization?
Zeitzen: It’s about transparency, and this is the real key. If you can be transparent about how you produce and how your product is impacting the environment and also about the social impacts that are potentially connected to your product, then you can work against this. You can improve on this, and at DNV, we go into the engine room of the companies in production, into the aluminum mines, into the steel production facilities and figure out if a claim holds water.
We are going into the supply chain and analyzing if there are human rights violations in there. We are going and looking at what the supply chain does. We don’t want to just see the documentation. We actually go and have a look. We do this across different industries about 25,000 times a year with the suppliers of our customers. It’s very old-fashioned, but if there’s, for example, possible child labor involved somewhere, we want to go and see, experience how a company is managing its environmental and social impact if they want to be a supplier to one of our customers. So, we are sent out anywhere in the world.
So, basically, just boots on the ground kind of verification?
Zeitzen: Yes, it’s boots on the ground. We are starting to see that also in the assurance world; you can deploy digital tools for that, but nothing beats on-site confirmation.
Because even if you have a sensor in some production site that tells you so-and-so much steel of a certain quality has been received, you need to also make sure those sensors and the processes around these are managed well. We don’t want to appear like the police, but in a sense, we are policing what they’re doing — helping to build trust across the supply chain ecosystem. Looking at supply chain resilience around the world, companies need to build and maintain these ecosystems with their suppliers.
Manufacturers want to have something from their suppliers. And what they want to have is resilience, reliability on the quality and the timing of deliveries, over and above technical product performance. You only get this these days with ongoing engagement.
What’s been the industry reaction to your role in advocating this more robust sustainability and risk management strategies?
Lilholm: DNV’s legacy since 1864 is risk management. Now, these risks extend into environmental, social and governance risk. At DNV, we have management systems that take care of some of the governance part, but also, in terms of risk management, we quantify risk.
For example, what’s the environmental performance of a supplier? How is a supplier claiming something? How can you trust your supplier and proactively work with your supplier mitigating these risks? We can provide that as part of enabling engagement with suppliers in this risk. If you are betting your future possessions to buy your materials from one supplier and they’re going to say, “We are going to invest heavily in changing our plant design,” and on this basis our products will become more sustainable – how will you know that you’re going to get the outcome? Is it feasible? You’re going to need expertise; you’re going to need a risk management approach to assess it.
And then we move into the area of opportunity as well because of optimization. We, of course, want to remove adverse impacts, but we also want to identify areas to create positive impact. DNV supports its clients on the digital transformation type of engagement where we can identify opportunities as well.
We like to cover risks and prevent them. We like to size risk, define and make proportional efforts according to risks. And that’s where many companies may struggle if they try to identify things in the supply chain themselves. Manufacturing companies are good at manufacturing, they are not rooted in risk management or being risk professionals at large, so they might look for the wrong things when they try to address a risk.
With DNV, as a professional risk management company, we are experienced in identifying, mapping, managing and monitoring risks and working with suppliers on resolving and reducing risk through defining risk protocols and audit programs and ultimately lower the risk exposure and enable the long-term resilience of the companies that we work with.
Lightning is one of the most expensive — and underestimated — threats facing the wind industry today. As turbines grow taller, their vulnerability to lightning strikes is only increasing. The average tip height of these structures has surged from less than 100 meters in 2000 to 164 meters in 2022, tripling the capacity per turbine. But with this growth comes a new risk: The towering blades are now more susceptible to lightning strikes [1] as they rise taller and cover larger swept areas than ever before.
The average wind turbine in the United States is struck at least once a year, and wind farms in the worst locations can average more than 10 strikes per turbine annually. The industry loses more than $100 million each year to lightning-related turbine repairs, according to recent estimates. Damages range from minor blade punctures to full structural failures, driving costly downtime, expensive maintenance, and, in some cases, full blade replacement.
Figure 1: A turbine with ALP 20 applied for a field test spins during a lightning storm.
Why Traditional Systems Struggle
Wind-turbine blades are equipped with lightning protection systems (LPS) designed to safely conduct lightning strikes to ground. The typical LPS consists of surface-mounted receptors connected to down-conductors embedded inside the blades. When working as intended, the receptors provide a preferential location to form an upward lightning leader — the initial channel of ionized air that initiates and determines the path of a lightning strike. When that upward leader connects to a downward leader from a charged storm cloud, a continuous path to the cloud is formed, and the full charge of the strike is safely transferred.
In real-world lightning events, the LPS doesn’t always function as intended. Instead of leaders forming solely at the lightning receptors, they often emerge directly from the down-conductor inside the blade — and at multiple points along its length. These internal leaders can pierce through the blade shell and gradually degrade its insulation. Occasionally, one of these internal leaders “wins the race” to the cloud, connecting before the leader from the receptor. When that happens, the resulting lightning strike can punch a hole through the shell, leading to delamination, structural damage, or — though rarely — complete blade failure.
Current LPS designs do offer protection, but not consistently and not without risk. No lightning protection method is 100 percent effective.
Figure 2: Before a strike, multiple upward leaders emanate from the blade, all racing to connect with the downward stepped leader from the cloud.
A Different Way to Think About Protection
Arctura, for example, is rethinking the way turbines deal with lightning — not just accepting it as inevitable damage. The company has developed technology that works to safely guide lightning’s path, instead of trying to fight it. After years of research and development, Arctura has created a coating designed to enhance the performance of LPS and significantly reduce the frequency of blade damage caused by lightning. Arctura is bringing this innovation to market in partnership with Mankiewicz Coating Solutions, LLC.
Protecting a blade with better insulation at the extreme electric fields presented before a lightning strike can be a fool’s errand. A better approach is to guide lightning to the receptors where it can be safely dealt with. That’s the idea behind the ArcGuide® coating technology developed by Arctura and found only in the Alexit® BladeRep® Topcoat ALP 20 by Mankiewicz. In the microseconds preceding a strike to a wind turbine, there are multiple upward lightning leaders forming inside and outside the blade and along its surface all reaching up toward the sky. Which one will win this rapid race to connect with the charged cloud is not clear, yet the outcome makes all the difference between a safe strike or a damaged blade. ALP 20 gives the receptors a competitive edge by encouraging the formation of upward leaders there, helping them win the race.
Figure 3: High voltage lab testing simulates the electric field the moment before a lightning strike. A square panel with receptor at center representative of a wind-turbine blade shell is coated on only one half with ALP 20. The increased leader strength on that side demonstrates how the coating enables to receptor to be more receptive.
How the Coating Works
At the core of ALP 20 is a proprietary formulation of small conductive particles suspended in a durable polyurethane-based coating. Years of empirical high voltage testing have resulted in an optimized set of coating characteristics found to be highly effective. The conductive particles in the topcoat create localized zones of stronger electric field strength that promote the early ionization of the air adjacent to the particles and above the surface. As the electric field builds, these patches of ionized air coalesce to form a continuous leader in the form of a surface flashover. When applied around receptors, this enables the upward leaders there to form faster, extend farther, and outcompete the undesired leaders forming inside the blade in the race to connect with the cloud.
Laboratory testing shows the difference: Blades coated with ALP 20 generate leaders that grow over four times faster than untreated blades. The faster a leader grows, the better its odds of connecting first and preventing damage.
Importantly, ALP 20 is not a conductive coating. Unlike a continuous conductive paint, all the electric energy travels through a highly conductive channel of ionized air above the surface. Because of this, the coating is not sacrificial and is not damaged by lightning strikes. High current laboratory testing confirms no degradation of the coating, even after multiple 200kA “full threat” strikes.
That means one application can protect a blade for its full-service life — eliminating the need for regular inspections, repairs, or reapplication.
Figure 4: Composite photos of multiple initial leader attachment tests on a blade tip show the same blade goes from failing to passing the test after application of ALP 20.
Proven in the Lab — and in the Field
Over four years, funded in part by the U.S. Department of Energy, the technology was subjected to rigorous testing protocols aligned with IEC 61400-24, the international standard for wind-turbine lightning protection.
In comparative testing that went beyond IEC standards and used aged wind-turbine blades, uncoated blades performed poorly — suffering numerous shell punctures during simulated lightning strikes. When the same blades were coated with ALP 20, punctures were significantly reduced under identical test conditions.
Annual drone inspections of ALP 20 installations on wind farms since 2022 show no degradation after multiple seasons of operation.
Lightning is highly unpredictable, and accurately forecasting the path of a strike is extremely challenging. This makes it equally difficult to assess the effectiveness of lightning protection technologies with high confidence. While laboratory tests can simulate where lightning leaders may attach, they have limitations — particularly in missing any impact of blade rotation. Despite these constraints, after conducting hundreds of simulated strikes, enough data was gathered to project a 73 percent reduction in damaging lightning events during real-world operation.
With just a single application of the coating [2], the potential for operational cost savings is significant.
Easy Application, Long-Term Payoff
A major advantage of ALP 20 is its easy installation. The flexible two-coat system can be applied by rope access teams or bucket truck crews during routine maintenance. Its application process is identical to that of BladeRep® Topcoat 12 — a widely used aftermarket coating applied to thousands of blades — and involves the following steps:
1. Prep: Sand the area around the receptor and clean thoroughly.
2. Paint: Mask off an area around the receptor and apply the first coat with a roller, wait 45 minutes, and then apply the second coat.
3. Cure: Allow a minimum four-hour cure time (conditions depending).
The system comes pre-packaged as a 1kg two-component kit in a single container with optional thinning for specific environmental conditions. One container is sufficient for the typical application on a single blade. Because the coating isn’t consumed during a strike, operators can expect ALP 20 to provide many years of worry-free lightning protection.
Redefining Lightning Protection
Reacting to the threat of lightning shouldn’t just be a matter of damage control — it should be about reducing downtime and optimizing performance. By incorporating the innovative ArcGuide® technology, ALP 20 enhances the electric field in the air above the surface around the receptors shifting the odds of strike attachment dramatically in favor of the existing LPS, making today’s turbines safer, more resilient, and cheaper to maintain.
As turbines continue to grow taller — and lightning events grow more frequent with climate change — LPS enhancements like ALP 20 could become a standard feature for both new builds and retrofit upgrades across the wind-energy landscape. Safeguarding the future of clean power means not just resisting nature’s power — but working with it. It’s a principle that dates back to Benjamin Franklin, whose invention of the lightning rod in 1752 marked a turning point in how structures are protected by guiding lightning safely to ground. Just as Franklin’s insight transformed building safety, innovations like ALP 20 offer a modern solution for wind turbines — harnessing that same philosophy to protect today’s infrastructure for tomorrow’s energy needs.
References
Said, Ryan, et al., “A Multiyear CONUS-Wide Analysis of Lightning Strikes to Wind Turbines,” Wind Energy, 2025.
Szlatenyi, Christopher, et al., “A New Coating for Reducing Wind Turbine Blade Lightning Damage,” International Conference On Lightning and Static Electricity 2022, 2022.
In 2023, the wind-energy sector celebrated the landmark figure of 1 TW of global installed capacity. This milestone was a testimony to the fundamental role played by wind energy in decarbonizing the global power system and helping the world reach its climate and energy goals. It took 40 years to reach the 1 TW milestone; however, according to estimates from Global Wind Energy Council (GWEC), the next terawatt installation is projected to take less than seven years on account of high growth forecast for the wind industry amidst the target net zero emissions by 2050. While the electricity generation from wind is increasing year after year, significant capacity addition, with a 17 percent average annual generation growth rate, is required to realize approximately 7,400 TW/h of wind electricity generation by 2030 (IEA).
The growth of the wind industry is duly supported by development of new technologies that enable it to harness more energy with high efficiency. Incidentally, the industry is also facing a compelling issue in end-of-life management of decommissioned rotor blades. (Courtesy: Shutterstock)
The growth of the wind industry is duly supported by development of new technologies that enable it to harness more energy with high efficiency. Incidentally, the industry is also facing a compelling issue in end-of-life management of decommissioned rotor blades. It is estimated that 85 percent of the components of a wind turbine can be recycled and re-used except the rotor blades, due to the non-recyclable thermoset matrix. In the last few years, new technologies have been developed that enable inherent recyclability in materials. The Recyclamine® is a disruptive technology platform that enables recyclable epoxy thermosets. Importantly, the technology is adaptable to existing rotor blade manufacturing processes, thus eliminating the need for design or operational changes to implement.
Figure 1:The evolution of adhesive technologies.
The wind industry has been instrumental in leading and taking a leap forward towards addressing the sustainability concern with successful implementation of Recyclamine® technology and development of world’s first recyclable rotor blade. The latest development of Recyclable epoxy adhesive system complements 100% recycling of rotor blade driving circularity.
Evolution of Adhesive Technologies for Rotor Blades
A wind turbine rotor blade generally consists of two shells bonded together with a structural adhesive, also called a bonding paste. The adhesive is load bearing; therefore, higher mechanical performance is required and, consequently, epoxy adhesive systems are used. Further, the profile of rotor blade and the application process necessitate the adhesive to be slump resistant, exhibiting low curing shrinkage and higher resilience.
Figure 2: Fatigue behavior of recyclable epoxy adhesive system.
Over the years, adhesive technologies have evolved with the development of new blade designs and the growth of the offshore platform (Figure 1). The conventional epoxy adhesives were designed with resin and hardener components that were thixotropic and mechanically reinforced. These adhesives provided optimum performance properties; however, the processability by a two-component dispensing machine caused increased wear on the parts and drives. This concern was addressed by the development of instant thixotropic adhesive that are comprised of low viscosity, flowable resin, and hardener components, which, on mixing, provided the same level of thixotropy as conventional adhesive. Increase in blade lengths resulted in development of slow reacting-high strength adhesive that enabled longer open time and low density adhesive that provided higher ductility, toughness, and lowered contribution to weight of the blade.
Recyclable Low Density Epoxy Adhesive
With the development of the world’s first recyclable rotor blade from the infusion system, the industry has taken a leap forward towards addressing the sustainability concern; however, since the majority of the rotor blades are constructed in two shells, it is imperative the epoxy adhesive is also recyclable.
Table 1: Comparative properties of non-recyclable and recyclable epoxy adhesive.
The recyclable epoxy adhesive system leverages from the Recyclamine® technology that enables debonding of the two shells under specific conditions facilitating recycling of the rotor blade. The adhesive aligns with the industry trend of longer, lighter, and aerodynamically stable blades. Process and performance properties of the recyclable low-density epoxy adhesive are comparable to the conventional low density non-recyclable epoxy adhesive in terms of rheological characteristics, working time, static, mechanical, and adhesion properties. (Table 1).
The fatigue behavior of recyclable low density adhesive system determined by plotting stress-number of cycles to failure (S-N) curve and slope exponent (Figure 2) also confirms equivalence to conventional structural adhesive (Figure 2).
Figure 3: Debonding of adhesive joint and recycling and recovery.
Debonding of Adhesive Joint for Recycling & Recovery
The proof of concept for the recycling of a wind blade is demonstrated by preparing an adhesive joint simulating the joining of the two shells of rotor blade prepared by gluing two glass reinforced epoxy substrates made from recyclable epoxy infusion. The joint after immersion in solvolysis solution at the temperature range of 75-90°C, debonded with the cleavage of the epoxy adhesive followed by the cleavage of the epoxy infusion system used as a matrix for substrates.
The recycling process resulted in recovery of the glass fabric reinforcement and epoxy thermoplastic after the neutralization and coagulation of the solvolysis solution.
Figure 4: Circularity in wind industry with recyclable epoxy systems.
Conclusion
A wind turbine rotor blade made from a recyclable epoxy resin system and the recyclable epoxy adhesive system can be fully recycled by a low-energy solvolysis process. The recycling leads to recovery of the epoxy matrix as a thermoplastic and the reinforcement such as glass or carbon fabrics in cleaned form.
The thermoplastic recovered from the recycling process can be re-used and re-purposed to manufacture thermoplastic objects, whereas the reinforcements can be re-used to manufacture new composite parts.
The comparative life cycle impact assessment studies (LCIA) of wind-turbine rotor blade made from Recylamine® enabled recyclable epoxy system and recyclable adhesive indicatesa more than 35 percent reduction in the global warming potential measured in terms of gm CO2 equivalent, vis-a-vis a wind-turbine rotor blade made from conventional, non-recyclable epoxy systems.
Further, the 100 percent recycling of wind turbine rotor blade enables a closed loop and drives circularity by transforming from linear economy, cradle-to-cradle (C2G) to circular economy cradle-to-cradle (C2C), (Figure 4). Importantly it addresses the wind industry‘s global concern on end-of-life management of wind-turbine rotor blades.
RES, the world’s largest independent renewable energy company, has developed or constructed 28 GW of renewable energy projects globally, reinforcing the urgent need to modernize grids and streamline permitting as electricity demand surges.
Announced ahead of Intersolar Europe in Munich, the milestone reflects growing power demand driven by AI, industrial electrification, and economic growth. RES now also supports 43 GW of operational assets through its expanding services business, underscoring the increasing maturity of the sector.
With operations in 24 countries and more than four decades of experience across wind, solar, battery storage, and green hydrogen, RES is calling on policymakers to accelerate infrastructure investment and enable affordable, secure, and clean energy at scale.
RES has reached a renewable energy milestone. (Courtesy: RES)
“The sector is developing and building faster and smarter than ever, but outdated grids and slow permitting are holding back progress — just as demand for clean, secure power is rising,” said Eduardo Medina, RES CEO. “We need systems that move at the speed of the challenge.”
Recent EU reforms offer a clear path forward, providing greater certainty and a more stable investment environment for renewable deployment.
“Germany has seen permitting for onshore wind increase sevenfold thanks to new EU rules,” Medina said. “Declaring renewables in the overriding public interest is a smart, pragmatic move. It’s working — and other countries can follow that lead. Solar now powers more than one in 10 homes across Europe and has become one of the most affordable new sources of electricity, as well as supporting hundreds of thousands of jobs.”
RES is developing an additional 26 GW of renewable energy projects, including in the U.S., where expansion of control center operation in Denver is under way.
Other highlights include entering the market in Brazil, Chile, and Mexico, and construction continuing on Nova Scotia’s largest wind project, Goose Harbour Lake.
RES supports calls from industry bodies including WindEurope for practical reforms that enable faster deployment and greater investor confidence in wind and solar, including applying new EU permitting rules more widely, filtering grid queues, making electrification easier, creating stable investment frameworks.
“We are ready to deliver faster, more flexible, and more affordable clean energy which benefits everyone,” Medina said.
American Wire Group has appointed Neal Hamer as the company’s director of engineering — power equipment.
Hamer will be responsible for driving AWG’s technical strategy and expanding the in-house engineering capabilities to support the growing power equipment segment. His role includes conducting a thorough assessment of AWG’s current technical landscape across transformers, switchgear, and substation solutions, while aligning supplier specifications with industry standards such as IEEE, ANSI, NERC, and UL. Hamer will be part of the development and scaling of the engineering team — including field, applications, and project engineers — to support sales, project execution, and customer needs.
Hamer has spent the last decade at Invenergy, where he most recently served as their electrical engineering director. In that role, he led a large team supporting the development and commissioning of renewable energy projects. He brings deep expertise in emergency fault troubleshooting, preventative maintenance for high-voltage equipment, and generation control systems.
“We are excited to welcome Neal to our team as director of engineering for all power equipment,” said Norman Russell, chief revenue officer at AWG. “At AWG, we’re constantly thinking about the future of the organization and how to better align ourselves with our customers’ needs — both in terms of scale and the types of solutions we deliver. With Neal joining our team, AWG has strengthened its position as a single source solution and industry leader for all wire, cable, hardware, equipment and accessories — making it easier and more efficient for our customers to execute projects efficiently and confidently.”
Clearway Energy Group and Clearway Energy, Inc. has completed its acquisition of the Tuolumne Wind Project in Klickitat County, Washington. The 137-MW wind farm has a strong operating history and generates enough reliable electricity to power more than 44,000 homes every year.
“We are thrilled to expand our investment in Washington state and provide reliable, low-cost power to homes and businesses on the West Coast,” said John Woody, Senior Vice President of Development at Clearway. “We look forward to our long-term partnership with the Turlock Irrigation District through this project.”
Tuolumne Wind generates enough electricity to power 44,000 homes per year. (Courtesy: Clearway Energy)
As a result of this acquisition, Clearway will contribute $1.3 million in annual sales and property taxes to Klickitat County to support local schools, hospitals, and other public services.
Located along the Columbia River, the project site has been recognized as one of the most productive wind resource areas in the western U.S.
The project will sell power under an amended agreement with Turlock Irrigation District, with an initial 15-year contract term and the option for a future repowering, potentially extending the project’s lifespan by upgrading turbine components.
This acquisition represents a $60 million investment in Washington, where Clearway’s existing footprint includes the 160-MW Rattlesnake Flat wind farm in Adams County.
Clearway Energy, Inc.’s portfolio comprises about 11.8 GW of gross generating capacity in 26 states, including 9.1 GW of wind, solar, and battery energy storage assets, and more than 2.8 GW of conventional dispatchable power generation providing critical grid reliability services.
Cerulean Winds recently announced its 1-GW Aspen floating wind project in the Central North Sea is expected to support more than 1,000 jobs and attract a total investment of 10.9 billion pounds across its 50-year lifespan.
Aspen is being delivered by world-class partners with technical expertise and experience in delivering large-scale offshore projects. Under a project charter, the contracting parties of the consortium (NOV, Siemens Energy, Bilfinger, Ocean Installer, alongside Haventus) anticipate directly creating more than 1,000 U.K. jobs, committing 1 billion pounds in domestic spending, and unlocking nearly 1 billion pounds in additional inward investment.
“This project has the potential to support thousands of skilled jobs and billions in investment to the U.K.; from a base in Scotland, Cerulean Winds and our delivery partners want to grasp the opportunity of creating a floating offshore wind supply chain industrial base in the U.K.,” said Dan Jackson, founding director of Cerulean Winds. “Having our delivery partners already in place, working together to a shared goal means that we’re able to accurately predict the benefits that Aspen can deliver.”
The Ardersier Energy Transition Facility will serve as the strategic hub for the Aspen project making it the U.K.’s first dedicated assembly, delivery and operations center for floating offshore wind (FLOW). By anchoring this vital part of the supply chain in Scotland, the project will help establish a fully integrated industrial ecosystem — ensuring that long-term economic value is retained within the U.K.
“The clean-energy transition is well underway in Scotland, thanks to state-of-the-art offshore wind projects, like this one at the Port of Ardersier, that will help us deliver on our Plan for Change and clean power by 2030 mission,” said Michael Shanks, energy minister. “Today’s commitment from Cerulean Winds and its partners shows exactly how this transition will bring good jobs and growth to Scotland, as Britain’s fast expanding renewable energy powerhouse.”
The 10.9 billion pound investment includes 5.9 billion pounds during development and construction and 100 million pounds annually during 50 years of operations. This expenditure is expected to provide 4.1 billion pounds in Gross Value Added to the U.K., 2.8 billion pounds of which will be in Scotland.
Once built, the three Cerulean Winds projects (Aspen, Beech, and Cedar), could comprise up to 300 turbines. The 1-GW Aspen site will be developed first, providing new offshore wind capacity helping to meet the U.K. government’s 50 GW by 2030 target.
Advanced Magnet Lab, Inc., a leader in the development of innovative magnet technologies, is offering supply chain and product solutions for permanent magnet customers through its manufacturing process that enables for a new frontier for permanent magnet applications.
This differentiator is PM-Wire™, a scalable and modular manufacturing process that can produce non-sintered and sintered permanent magnets at a high rate and high yield. This process is adaptable to a variety of applications, including those that benefit from magnets in unique configurations and material compositions, such as electric motors.
AML’s PM-Wire™ products include:
PM-Uniform: Straight, curved, ring, or helical magnets with transverse or radial magnetization.
PM-360: Straight, ring or helical magnets with “Continuously Changing Magnetization Direction.”
PM-Axial: Curved magnets with Axial magnetization allow for rotor topologies having breakthrough benefits.
AML’s non-sintered magnets have several material options, including Samarium Iron Nitride (SmFeN), Manganese Bismuth (MnBi), and other (bonded) neo magnet materials. AML is looking at additional materials to introduce within the PM-Wire™ offering.
AML’s sintered magnets have options such as Neodymium Iron Boron (NdFeB), which is common among traditional permanent magnet producers, and (Mischmetal-Nd)FeB. AML’s approach with (Mischmetal-Nd)FeB provides for permanent magnets with less critical rare earth elements and better traceability of inputs for end-use customers. AML is strategically aligned with several U.S. and global supply chain partners for magnet materials for AML’s permanent magnets.
AML has spent a decade developing some of the most advanced permanent magnet technology in the world, including manufacturing processes that maximize the use of existing magnet materials and processes that enable the use of new, lower-cost materials while meeting or exceeding the most demanding application requirements of electrical machines (motors and generators).
Combilift recently celebrated the 10th anniversary of the OEM Engineering Traineeship initiative. The event at global headquarters in Monaghan welcomed graduates, current trainees, and local educators, underscoring the program’s success, an initiative between Combilift and the Cavan and Monaghan Education and Training Board (CMETB).
A factory tour of Combilift. (Courtesy:Combilift)
Launched in 2015, the OEM Engineering Traineeship was born from a shared vision to tackle the skills gap in engineering and manufacturing with an industry-led approach. More than 150 trainees have achieved QQI level 5 qualification in the program, with job placement rates above 80%.
Combilift, a global leader in materials handling solutions, has been central to this success. As the primary industry partner, Combilift has provided workplace experience and ensured the course content remains aligned with real-world demands.
“We wanted to create more than just a training program — we wanted to build a pathway into meaningful careers,” said Martin McVicar, Combilift managing director.
The nine-month program blends 26 weeks of classroom-based learning at Monaghan Institute with 12 weeks of hands-on work experience in Combilift. Over the years, the course content has evolved to reflect changes in the manufacturing landscape, now including modules in hydraulics, lean manufacturing, and, more recently, mathematics, to prepare students for greater work or educational opportunities. CMETB has played a vital role in coordinating and delivering the educational aspect of the program.
“It’s about staying ahead of the curve,” said Sinead McKenna of CMETB. “We’ve created a flexible, forward-looking course that equips learners with in-demand skills and supports local industry at the same time.”
Fully funded through government and EU support, the plan removes financial barriers for participants and trainees are offered a 300 euro bursary per week during practical placements within Combilift. Trainees also benefit from additional qualifications, including City & Guilds module in Hydraulics and a Lean Six Sigma White Belt.
The 10-year milestone was marked not only by reflection but by ambition for the future. Attendees at the celebration event heard first-hand from past graduates who have gone on to build thriving careers, many still with Combilift, some progressing to degree-level study or engineering apprenticeships.
“The demand for talent in this sector is only growing, and we’re proud to continue building that talent right here in Monaghan,” McVicar said.
KASK recently introduced the Zenith X2 Max, an industrial safety helmet for a wider range of head shapes.
The Zenith X2 Max is an industrial safety helmet that accommodates different head sizes. (Courtesy: KASK)
Head protection now maxes out at 63 centimeters, leaving many workers without a safe, comfortable fit. With a design based on biometric research, the KASK helmet ensures the high level of protection KASK is known for, and also a secure and comfortable fit for a wide range of users.
The new Zenith X2 Max, an addition to the Zenith X Series, is made with a longer chinstrap and a larger internal and external shell, accommodating longer faces and worker head sizes up to 66 centimeters, ensuring the maximum protection and comfort for everyone.
The VIKING YouSafe™ Cyclone suit joins a growing portfolio of VIKING PPE whose fit and features reflect the safety needs of female seafarers, pilots, and technicians in the marine and offshore industries. Delivered in high-vis GORE-TEX NARVIK, the female-fit YouSafe Cyclone suit is approved to the same dual SOLAS/MED and CE/ISO standard as the male version and is available in multiple sizes. Common features include compatibility with all standard offshore harnesses, durable Neoprene cuffs and neck seal, retro-reflective piping for increased visibility in dark surroundings, and a maintenance free zipper.
The new design offers more safety and comfort for women. (Courtesy: Viking)
The most recent U.K. Government Industrial Strategy Offshore Wind Sector Deal study included a “minimum target” for one third of the industry’s workforce to be by 2030 (2018 – 16 percent). In U.K. waters, and elsewhere, getting the right PPE in place to best serve the safety needs of women offshore has become a focus for equity and inclusivity strategy at Ørsted, Siemens, and Vestas.
“As a young industry, offshore wind offers a huge opportunity to change attitudes in the workplace, and to encourage the diversity, equity and inclusion women are entitled to expect,” said Lasse Hansen, senior HSE manager, PPE and TMSE, Ørsted. “Ørsted has identified female-specific PPE as part of the critical infrastructure we need for women to work safely offshore today and a necessity to attract more of them into this industry. We were delighted to work with VIKING as one of our key safety solution providers to take a significant step in the right direction.”
Ratios and cut are redesigned for shorter torsos, and different hip and chest proportions, and for a range of smaller sizes that avoid the risk of snagging in fixtures and fittings. The sleek design also offers a high level of comfort and enhances the safety of women when stepping or jumping to and off the platform, climbing the tower or moving around the nacelle. In addition, the suit includes integral braces, which hold suit pants for free leg movement when climbing and allow the wearer to doff its top part to move around freely.
Poul Parning, senior EQS PPE Specialist, Siemens Gamesa, said the Cyclone suit was a welcome contribution to its efforts to attract more women to offshore wind, ensuring that outdated practices did not frustrate career progress. “There has been an intense focus on PPE as a diversity, equity, and inclusion issue at Siemens Gamesa for the last two years; we have already adopted a new safety harness for women,” he said. “The Cyclone CTV suit supports corporate goals.”
“At Vestas, we believe that diversity and inclusion go hand-in-hand with innovation, and that everyone must feel safe, valued, and that their voice is heard,” said Vestas Wind Systems HSE manager Peter Armstrong-Cribb. “The right PPE puts these beliefs into practice.”
Greene Tweed, a global manufacturer of high-performance sealing solutions and engineered components, has showcased its Seal-Connect® portfolio, a comprehensive range of high-performance electrical connectors engineered to meet the most demanding conditions in the energy sector. Trusted by the world’s largest oilfield service companies, Seal-Connect products provide reliable signal integrity and power transmission, even in extreme environments.
The Seal-Connect portfolio includes designs for drilling, completions, and production applications. (Courtesy: Greene Tweed)
The Seal-Connect portfolio includes designs for drilling, completions, and production applications. With decades of research and innovation, Greene Tweed offers connectors rated up to 260°C (500°F) and 45,000 psi, ensuring performance in high-pressure, high-temperature (HPHT) conditions. The portfolio encompasses solutions, including:
Single-Pin Connectors: Ideal for precise power and signal transmission.
Multi-Pin and KTK-Style Connectors: Designed for versatility in complex applications.
Rotatable and Wet Stab Connectors: Engineered for rugged environments, including submerged conditions.
Custom Solutions: Tailored to meet unique customer requirements with the support of advanced 3D modeling, rapid prototyping, and extensive testing capabilities.
At the core of Seal-Connect is Greene Tweed’s expertise in materials science. The connectors leverage proprietary materials such as Arlon® PEEK and Chemraz® FFKM, offering superior resistance to chemicals, extreme temperatures, and mechanical stress. Each product undergoes testing at ISO-certified facilities to ensure reliability and compliance with industry standards.
Backed by more than 80 patents, the Seal-Connect portfolio stands as a testament to Greene Tweed’s dedication to advancing electrical connection technology. With a global presence and local expertise, the company continues to support industries where performance and safety are paramount.
Liebherr recently signed an agreement with Swedish simulator manufacturer Tenstar Simulation for the development of mobile crane simulators.
The agreement, signed at Bauma, follows the introduction of its first crane simulator in 2024. The current simulator replicates the real LTM 1060-3.1 and includes crane setup functions and hook block assembly procedures.
Daniel Pitzer of Liebherr (left) and Freddy Lund of Tenstar. (Courtesy: Liebherr)
The system incorporates three screens, master controls, a moving platform seat and VR goggles, with training programs available in 25 languages covering crane functions including slewing, lifting, telescoping, and luffing operations.
“We have worked with Tenstar on an equal footing from the very beginning and are delighted to continue this partnership in the future,” said Daniel Pitzer, Liebherr commercial director.
“Our aim is to create a simulated crane world with Liebherr and various other crane models,” said Freddy Lund, Tenstar chief executive.
Based in Sweden, Tenstar Simulation specializes in developing training simulators for the construction and material handling industries. The company’s crane simulators feature 4D technology with moving platforms and virtual reality capabilities.
Daughter craft can meet growing demand for offshore wind vessels in challenging environments across Europe and APAC, according to a report from Chartwell Marine.
As the offshore wind industry scales to meet ambitious capacity targets, there is a growing demand for vessels that can operate effectively in environments far from shore, Chartwell Marine’s report said.
Next-generation daughter craft are smaller and more adaptable. (Courtesy: Chartwell Marine)
“To complement CTVs and SOVs and help meet growing vessel demand, the offshore wind industry urgently needs an innovative solution,” said Andy Page, Chartwell’s founder and managing director. “For too long, we’ve taken a bigger-is-better approach to vessel procurement, but it’s time for us to ‘scale down to scale up.”
By integrating the core strengths of CTVs into a smaller, more adaptable vessel, Chartwell argues next-generation daughter craft will create significant efficiencies for offshore wind vessel operations across the following areas:
Transporting crews quickly, comfortably, and safely around offshore wind farms from SOV motherships anchored on site — eliminating the conventional two-hour CTV roundtrip to and from shore.
Maximizing the reach of an on-site SOV, by enabling technicians to simultaneously service multiple wind turbines, cutting overall deployment times substantially.
Providing a designated safe refuge or emergency rescue option in situations where the SOV is required to operate beyond a two-hour safe recovery range.
Acting as a temporary nearshore CTV, taking on less demanding logistical charters for wind farms located closer to shore.
“Working with Chartwell Marine to create the ultimate offshore wind daughter craft has been an absolute pleasure,” said Andrew Duncan, North Star renewables and innovations director. Daughter craft, on average, can be built for around 25 percent of the cost of a typical CTV and take 6-8 months to build — half the time of a traditional CTV.Furthermore, they can be built efficiently by local boatyards using standardized construction kits and off-the-shelf components — helping to satisfy local content requirements in APAC and other markets.
A Californian construction firm has become the first to take delivery of a “game-changing” machine.
Cox and Cox Construction, a full-service underground utility contractor licensed in California and Nevada, is the first company to operate a Bulldog trencher.
Buddy Cox, Cox and Cox president, with a Mastenbroek Bulldog. (Courtesy: Ditch Witch West)
The compact, powerful and agile trencher was designed by U.K. manufacturer Mastenbroek specifically for American utility contractors and is marketed on the West Coast by Ditch Witch West.
Mastenbroek designed the Bulldog for underground utility installation, particularly in areas where overhead electrical cables could cause or be destroyed by forest fires.
Cox and Cox Construction’s search for the Bulldog began in 2023 when the company’s president, Buddy Cox, identified the need to acquire a smaller, faster trencher to give him a competitive advantage when tendering undergrounding contracts. He discovered the Bulldog after speaking to Ditch Witch West, which was negotiating sales rights for Mastenbroek machines with its US sales agent, Port Industries.
Cox and Cox Construction took delivery of the first production Bulldog trencher late last year and began using it in January 2025 to install underground utility cables along 50 miles of narrow, winding roads near Lakehead in northern California.
“The Bulldog is a game-changer,” Cox said. “It trenches so quickly and so cleanly. It’s fast, easy to mobilize, and produces an accurate trench, even on uneven, narrow roads. It is also so comfortable to operate. Our driver loves being in the cab. It’s large, and the controls are in exactly the right places. The conveyor system is the best on the market. We’re leaving a really clean surface, and we can cut at both 10 and 18 inches, with the flexibility to change over very quickly. The Bulldog is certainly the fastest and best trencher in its class.”
The Bulldog, which is 10.9 meters (38 feet 7 inches) long and has a transport width of 2.5 meters (8 feet 2 inches), borrows much of Mastenbroek’s engineering prowess from the company’s 17/17 trencher, which is popular with European undergrounding contractors.
A US EPA Tier 4 final compliant Volvo 8-liter engine powers The Bulldog, along with a new diesel hydrostatic drive system developed by Mastenbroek to power the new mechanism. The new heavier digging trencher, which can comfortably achieve the 1.5 meter (five-foot) trench depth required by U.S. cable-layers. The Bulldog also features an offset cutting head, which uses rotary carbide digging picks that offer smooth rotation and long lifespans.
The new digging mechanism also contributes to the Bulldog’s light weight, just 21,300 kilograms (47,000 pounds), which is some 6,800 kilograms (15,000 pounds) lighter than its nearest rival. Mastenbroek’s engineers have ensured Bulldog’s weight distribution is even, allowing its 248 bhp to be directed efficiently into the trench for maximum productivity.
“Utility contractors are in desperate need for something like the Bulldog,” said Eric Greene, general manager California at Ditch Witch West. “They have thousands of miles of undergrounding to deliver, and it’s hard going. Until now, there has not been a trencher that is robust, reliable, and capable of working at the speed needed. We think the Bulldog is going to be incredibly successful, and we’re super excited to have exclusivity along the West Coast where so much undergrounding work is being undertaken.”
Christopher Pett, Mastenbroek’s commercial director, is equally optimistic.
“The Bulldog has been inspired by the unique challenges faced by North American contractors looking to install underground cables as quickly and cost-effectively as possible,” he said. “We have a tradition of innovation and developing solutions that meet our customers’ needs, and the Bulldog continues that.
We are delighted to see our first Bulldog working on a live job site and are confident this will be the first of many that Ditch Witch West sells to contractors delivering the thousands of miles of undergrounding needed along the West Coast.”
Crane Service Inc. purchased an LG 1800-1.0 lattice boom crane at Bauma 2025, the construction trade show. This purchase further strengthens the partnership between the two companies and expands the capabilities of Crane Service Inc. for its customers.
Crane Service Inc. operates in 35 states. (Courtesy: Liebherr)
Crane Service Inc. has served as a leader in the crane industry since 1960 and operates in 35 states spanning the contiguous United States. With a fleet including more than 15 different models of Liebherr cranes, Crane Service Inc. provides full service heavy lift and rigging solutions across a range of applications. This machine will be the third LG 1800-1.0 in its fleet and is set to work on wind-farm sites assisting with maintenance and construction of wind turbines across the nation.
Liebherr lattice boom cranes have been enhanced for use in the wind industry with a large selection of boom configurations allowing for use on the latest generation of wind turbines. This, paired with the all-terrain chassis built into all Liebherr LG cranes, gives operators maneuverability on site as well as an ideal configuration.
The LG 1800-1.0 also comes equipped with WindSpeed load charts, increasing safety and allowing operators to perform lifts in conditions with higher wind speeds with peace of mind.
North Star, a service operation vessel operator in Europe’s offshore wind sector, has become the first organization to have ships achieve Lloyd’s Register’s Cyber Resilience classification, in line with mandatory International Association of Classification Societies (IACS) standards implemented for all newbuilds beginning July 2024.
North Star ships are the first to achieve Lloyd’s cyber resilience classification. (Courtesy: North Star)
North Star’s new commissioning service operation vessels (CSOVs), the Grampian Kestrel and Grampian Eagle, gain stronger ability to withstand cyberattacks, continue operating under threat, and recover quickly from incidents, ensuring the protection of personnel and onboard systems, while maintaining critical offshore operations.
These CSOVs are the first in the world to be formally approved by Lloyd’s Register to the LR Rules implementing IACS standards UR E26 (‘Cyber Resilience of Ships’) and UR E27 (‘Cyber Resilience of Onboard Systems and Equipment’).
They represent North Star’s first CSOV additions to its growing renewables fleet in its ambition to add 40 SOVs by 2040.
“Being the first to certify our newbuilds under these new IACS standards demonstrates our commitment to safe, smart, and sustainable offshore operations,” said Gard Talmo, North Star CEO. “Working in partnership with VARD and Lloyd’s Register has been instrumental to this process, and I’m very proud of North Star’s IT and special projects team’s drive to advance our CSOVs’ cyber resilience, positioning us ahead of the curve as the sector evolves.
We’re ready to support the next phase of Europe’s offshore wind growth, and we’re doing it with trust, security, and future-proof thinking built in from the keel up,”
“Cyber resilience is no longer optional, it’s essential,” said James Bradford, North Star chief technology officer. “That’s why our newbuilds are equipped to withstand, recover from, and adapt to cyber incidents.”