GEO-Instruments are working with Keller and Bauer Technologies on the construction of a monopile manufacturing facility in Teesside.

Surveyor setting-out pile locations
Surveyor setting-out pile locations on site near piling rigs

The project

Bauer and Keller joint venture (BKJV) are installing piles for a massive new factory that will manufacture bases for offshore wind turbines.
The bases, known as monopiles, are large steel structures that will form part of the foundation for wind turbines to be installed in North Sea wind farms.

The completed factory, owned by SeAH Wind, will be the largest of its kind in the world and is expected to produce more than 100 monopiles each year. 

The challenge

BKJV are to install around 1,500 bored piles and approximately 5,500 CFA piles across the 36 hectare site. The piles are installed to designed depths between 28 and 35 metres below ground level. There have been up to 15 piling rigs running concurrently

GEO-Instruments are working independently for BKJV, supplying setting-out services and as-built reporting.

The project requires a large volume of data to be collected and processed quickly to keep the site programme moving, making it a demanding project for the GEO-Instruments team.

The solution

GEO-Instrumnets Site Engineers coordinated the eight setting-out engineers in teams, working closely with BKJV to manage the process and issue as-built reports as efficiently as possible

The Site Engineering team use Leica iCON robotic total stations. Having access to these specialised tools makes engineering work easier, faster and more efficient, especially when it comes to working with the construction of bearing piles.

Project facts


SeAH Wind

Keller business unit(s)

Keller Foundations

Main contractor(s)