Manufacturing blueprint maps route to UK floating wind facility

A Gloucestershire engineering company has drawn up plans for a new UK manufacturing facility that could create up to 40 skilled jobs and help supply the rapidly growing floating offshore wind sector in the Celtic Sea.

Gabriel Engineering Group Ltd has partnered with the National Manufacturing Institute Scotland (NMIS) to explore how specialist anchoring and mooring systems, essential components that secure floating offshore wind turbines to the seabed in deeper waters, could be manufactured competitively and at scale in the UK.

Supported through The Crown Estate’s £50 million Supply Chain Accelerator programme, the project explored how the UK could secure a greater share of the manufacturing, employment and economic benefits of floating offshore wind.

The work comes as the UK’s offshore wind supply chain is expected to contribute more than £18 billion to the economy over the next decade^[1]. With the Celtic Sea becoming one of Europe’s most promising regions for floating offshore wind, the project assessed how UK manufacturing capability could be developed to supply the specialist anchoring and mooring systems required to support future gigawatt-scale deployments.

NMIS worked with Gabriel Engineering to map how the systems could be manufactured efficiently and at scale, analysing materials, labour, equipment and production requirements. Using digital manufacturing models, production simulation and cost analysis, the team tested different production scenarios and identified what would be needed to establish a commercially viable UK manufacturing operation.

The project also considered where a new facility could be situated, assessing 10 potential port locations including Milford Haven, Port Talbot, Cardiff and Falmouth. Locations have now been identified for further engagement, based on factors including access to skilled labour, available land and infrastructure capable of handling heavy materials and finished products.

Gabriel Engineering also worked with Bardex® Corporation to explore how its BarLatch® and BarMoor® technologies could be produced through a modular manufacturing approach. Components would be manufactured and tested before final assembly, helping to identify technical issues earlier, reduce manufacturing risk and improve efficiency as production volumes increase.

The findings are now supporting Gabriel Engineering’s and Bardex’s investment and commercial planning, including discussions with The Crown Estate on the next phase of the project. If developed, the proposed facility could deliver up to 40 skilled jobs by 2028, support further employment across the regional supply chain and establish a new UK manufacturing base for critical floating wind infrastructure.

Jason Simeon, chief executive officer at Gabriel Engineering, said: “Our collaboration with NMIS has been a turning point for Gabriel Engineering. By focusing on a modular process approach, we’ve been able to integrate these high-performance products into a system designed for the factory of the future. We have created a better production process that removes the inherent risks associated with large-scale fabrication, enabling us to deliver at the pace required by the offshore wind market.

“This project has never only been about products – it’s also about people and places. By pinpointing where we can build and the skills we will need, we are laying the groundwork for a facility that creates lasting, high-value jobs and helps regenerate the coastal communities at the heart of the Celtic Sea opportunity.”

Graeme McLaughlin, design engineering team lead – Digital Factory at NMIS, said: “Gabriel Engineering came to us with a clear ambition to enter the floating offshore wind market. Our job was to work out what manufacturing at scale could actually look like – from the production process and equipment requirements to costs, factory layout and location.

“The result is a practical framework that gives Gabriel Engineering the evidence to make investment decisions and pursue commercial opportunities. As floating wind grows, this kind of manufacturing planning will be critical if more of the infrastructure can be made here in the UK.”

NMIS is operated by the University of Strathclyde and is part of the High Value Manufacturing (HVM) Catapult.

Ian Finch, director of business development – EMEA at Bardex Corporation, added: “The project with Gabriel Engineering, NMIS and The Crown Estate has created a blueprint for a high-value advanced manufacturing facility for our mooring connectors and related products. This could create long-term UK jobs while opening up a significant export market for our proven technologies at the volumes needed to build gigawatt-scale floating wind projects. We’re excited to continue working with Gabriel Engineering and The Crown Estate as this opportunity progresses into its next phase.”

[1] The Crown Estate