In June 2021, Ziking undertook the production of CSSC Haizhuang’s "Fuyao" floating offshore wind platform, a project contracted by Guangzhou Wenchong Shipyard Heavy Industry Co., Ltd. The platform measures 71.96 meters in total length, with a molded depth of 32 meters, a molded breadth of 80 meters, a designed draft of 18 meters, and a displacement of approximately 15,600 tons. Compared to fixed-bottom offshore wind turbine foundations, the "Fuyao" floating platform features larger dimensions, greater weight, and more complex internal structures, presenting higher manufacturing challenges and stringent quality inspection requirements.

The "Fuyao" floating wind turbine platform adopts a three-column semi-submersible configuration, consisting of columns, heave plates, lower pontoons, and upper cross braces arranged in an equilateral triangle layout. Ziking was responsible for producing the columns, lower pontoons, and cross braces.

The excessive weight of column segments exceeded the crane capacity in the workshop, while dividing them into smaller sections would increase later assembly difficulties. After technical analysis by the process team, an upright fabrication method was adopted. A specialized platform fixture was fabricated in the workshop, with its base transported via modular transporters. Once the column segments were completed on the fixture, both the fixture and segments were moved out together, bypassing crane limitations while improving fabrication efficiency.

The lower pontoon and cross brace segments, being block-shaped with large dimensions and extended lengths, posed challenges in welding difficulty and assembly precision. Through on-site technical evaluation, Ziking’s team implemented the inverted segment fabrication method and the integrated segment assembly method.

‌Inverted Segment Fabrication Method:‌ To minimize overhead welding, optimize welding conditions, ensure weld quality, and enhance efficiency, segments were fabricated upside down. After completing the top welds in a flat position, the segments were flipped for bottom welding, converting most overhead welds to flat welds. This reduced welding complexity and minimized scaffolding requirements.

Integrated Segment Assembly Method:‌ Multiple segments were constructed together in the workshop. After individual segment welding, they were transported outdoors for final assembly, ensuring precise alignment at joining interfaces and eliminating mismatches while significantly shortening the production cycle.

Composition diagram of lower floating body

The "Fuyao"

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From late June to early November 2021, Ziking’s Zhongshan Base overcame numerous obstacles, completing the production of "Fuyao" in nearly five months.

As the first floating wind turbine platform contract for both the Zhongshan Base and the company, conventional fixed-bottom offshore steel structure welding techniques and production management experience could not be directly applied. The team faced substantial tests in welding workload, process technology, welder proficiency, on-site quality control, and production management. Through collaborative efforts—studying technical documentation, refining welding procedures, and enforcing strict quality oversight—the base successfully resolved production challenges and delivered the project.

The successful fabrication and delivery of the "Fuyao" floating wind platform mark a breakthrough in Ziking's floating platform manufacturing capabilities, signifying a major advancement in the company's offshore wind turbine foundation offerings toward deeper-water applications.