Automated Grouting System Cuts Vessel Time and De-risks Offshore Wind Foundations

RaKon has unveiled a fully automated, purpose-built grouting rig that marks a major technological leap forward for offshore grouting projects. Designed to address long standing capacity, safety and quality challenges, the new system delivers up to 60 m³ of grout per hour, four times the traditional industry standard.

“The market offered no automated systems that delivered the capacity, consistency and quality assurance needed for tomorrow’s offshore wind, oil & gas projects. So, we built one,” says Joakim Navestad Hansen, Head of Grouting and Injection at RaKon. “Increasing capacity without compromising precision quality control saves clients significant vessel time and reduces operational risk.”

The modular containerized rig integrates mixing, pumping, monitoring and logging into one closed, automated unit. With stable, controlled pressure and continuous sensor-based QA/QC, the system ensures void free filling of critical foundation annuli while capturing real time data for full traceability, certification, and long-term documentation.

The automated rig has already been used for testing grout products by global materials supplier Sika and Y-Matec at AF Environmental Base Vats, Norway. Y‑MatTec, a Denmark‑based developer of Ultra‑High‑Performance Concrete, has used the rig as part of its DNV‑certified production process.

“Y-MatTec participated in one of the first trials of RaKon’s new generation of recirculating jet mixer.  The new-generation equipment is impressive due to its instrumentation and control of mixing and pumping.  The system worked well with our DNV type approved G900 product where consistent and predictable final strength results were obtained,” says Richard Elins LL.M, Sales Director I Y-MatTec. 

While testing is still at an early stage and fully automated mode has not yet been demonstrated, Sika has a positive overall impression of the grouting system.

“Fast and efficient installation of foundations—supported by equipment capable of high‑throughput mixing and the use of bulk-delivered offshore wind turbine grouts—is increasingly important for project success in the market. Any level of automation that contributes to consistent grout quality and performance can further support reliable installation processes”, says Michael Fisher, Head Offshore and Marine Construction EMEA in Sika. 

The innovation is more than mechanical. RaKon’s system introduces digitally driven, remotely accessible, automated grouting to an industry that has long relied on manual adjustments. Real time measurements and logging of density, pressure and flow enable predictable, repeatable operations, even in changing offshore conditions. 

Automation substantially reduces exposure to vibrations, noise, heavy lifting and deck based manual work, improving safety while increasing consistency. The design encompasses ease of operations and protection from elements for operating personnel.

“The rig is compact and easy to transport, built into a standard offshore container, and can be lifted offshore with minimal footprint,” says June Karin Hesby Vastveit, Business Developer at RaKon.