Uses of rubber in the offshore and wind industry

Globally, Europe and China lead development within the offshore and wind industry, with global capacity reaching over 80 GW. The UK is a global leader, operating 16.6 GW of capacity across 46 offshore wind farms in the UK and supporting 17.7% of the nation’s electricity. Major offshore, sea-based projects include Dogger Bank, located off the coast in North East England.

The UK offshore and wind industry employs over 40,000 workers across engineering, manufacturing and vessel operations, with the nation working towards 43 to 50 GW of offshore wind capacity by 2050.

As expert rubber manufacturers UK and global businesses choose to support their offshore and wind industry projects, Aquaseal Rubber manufactures bespoke products in a range of materials. This guide will highlight what the offshore and wind industry is, where rubber is used across subsea cables, foundations and substructures, and floating platforms, what materials are most suited and the best ways to maintain rubber for offshore and wind.

What is the offshore and wind industry?

The offshore and wind industry is a global sector which builds and runs wind farms in the ocean or deep lakes, using fast and steady sea winds to generate clean electricity from wind turbines. A major driver of the global clean energy transition, the offshore and wind energy industry pushes industrial manufacturing in Europe, Asia and the Americas. It plays a critical role in meeting international climate targets.

Certain materials are better suited for use in offshore and wind energy applications because they can withstand harsh marine environments, temperature changes, mechanical loads and other demanding operating conditions. These materials include EPDM, neoprene, nitrile/HNBR, viton and polyurethane plastic, which are used to manufacture a range of products including seals, gaskets and o-rings.

In the UK, notable companies operating in the offshore and wind industry include SSE Renewables and ScottishPower Renewables. They are involved in some of the biggest wind farms, including Dogger Bank and East Anglia, meaning they will use rubber materials within their operations to enhance operations and maintain health and safety standards.

Where is rubber used in the offshore and wind industry?

Operations in the offshore and wind industry involve harsh marine conditions, high pressures and extreme temperatures. Since thousands of people rely on energy generated from offshore wind farms, it is essential that the correct rubber materials are manufactured and installed in several applications.

Subsea cables

Subsea cables transfer electricity and data between offshore wind turbines, substations and the onshore grid. They play a critical role in transmitting power generated offshore.

They are exposed to seawater and salt, water pressure and different water conditions, including currents and waves. Installation, movement and operation can subject cables to mechanical stress over time, with chemicals and pollutants, marine organisms and UV exposure also causing potential problems.

Rubber is used to protect subsea cables from these various pressures to provide flexibility, waterproofing, abrasion resistance and protection against seawater, movement and mechanical stress. It can be moulded into seals, cable protection systems, bend restrictors and connectors to protect subsea cables.

Foundations and substructures

Foundations and substructures provide the structural support that connects offshore wind turbines to the seabed, transferring the turbine’s weight and operational loads into the surrounding ground. Types of foundation or substructure depend on water depth and site conditions, and can range from shallow steel monopiles to deep-water floating platforms.

Exposed to saltwater, waves and tidal forces, wind loading and vibration, as well as temperature changes and seabed movement, foundations and substructures must provide a steady base for wind turbines and other critical applications.

Rubber helps to absorb vibration, accommodate movement, prevent water ingress and protect components from impact and abrasion, with different rubber materials more suited to certain conditions. Watertight seals maximise performance in offshore and wind applications by precenting water ingress and internal damage from corrosion.

Floating platforms

Floating platforms support wind turbines in deeper waters where fixed foundations are impractical, using mooring lines and anchors to maintain the turbine’s position instead of attaching them directly to the seabed. This allows them to capture stronger winds far from the coast.

The conditions floating platforms are exposed to and surrounded by are constantly changing. From constant movement and dealing with mooring loads to temperature fluctuations and abrasion and mechanical wear, repeated engagement with these conditions can lead to fatigue as service life extends, running the risk of failure.

Rubber accommodates the constant movement and dynamic loading associated with floating platforms whilst providing sealing, vibration dampening and protection against harsh marine conditions.

What rubber materials are used in the offshore and wind industry?

Different types of rubber materials are used across the offshore and wind industry because each type has different properties, making them better suited to certain applications.

From choosing between rubber or polyurethane to ensuring watertight seals are performing optimally, bespoke rubber materials are critical in the offshore and wind energy industry. These materials include:

• EPDM: with strong resistance to water, seawater, ozone, UV radiation and weathering, EPDM is widely used for seals, gaskets, cable protection and hose components exposed to harsh marine and outdoor conditions.
• Neoprene: for components that need to withstand movement and environmental exposure, neoprene is used for seals, gaskets, vibration mounts and cable protection because it provides flexibility, mechanical strength and weathering resistance.
• Nitrile/HNBR: commonly used for o-rings, oil and hydraulic seals, gaskets and other fluid-handling components in wind turbines and offshore machinery, nitrile offers good oil and fuel resistance whilst HNBR provides enhanced heat, chemical, ozone and mechanical resistance for more demanding applications.
• Viton (FKM): used for high-performance seals, o-rings, gaskets and components within hydraulic and lubrication systems, viton is suitable for demanding offshore environments because of its resistance to high temperatures, oils, fuels and aggressive chemicals.
• Polyurethane: used to protect machinery from mechanical loads or repeated movement, polyurethane plastic is used in seals, rollers, cable protection and bump stops because of its excellent abrasion, tear and wear resistance. Using polyurethane is important in the offshore and wind industry because it is extremely durable, resistant and versatile.

At Aquaseal Rubber, we are proud to support clients operating in several industries worldwide by producing bespoke rubber solutions for their projects. A full list of the rubber we manufacture for offshore and wind energy applications can be found on our offshore and wind energy page.

What are the best ways to maintain rubber in the offshore and wind industry?

Maintaining rubber or polyurethane components in offshore and wind energy applications is crucial in avoiding expensive major repairs, ensuring a steady, reliable flow of clean power and preventing catastrophic equipment failures.

Rubber for offshore and wind energy can be maintained by:

• Conducting routine inspection and condition monitoring: regularly inspecting rubber seals, gaskets, mounts and other protective components helps to identify cracking, hardening, swelling or other signs of deterioration early, helping to extend service life.
• Regular cleaning and decontamination: removing salt deposits, dirt, oils, chemicals and marine contaminants helps to prevent substances from degrading rubber surfaces over time, with appropriate cleaning methods helping to preserve flexibility, sealing performance and overall resistance.
• Ensuring surface protection and coatings: protective polyurethane coatings can shield rubber components from UV exposure, seawater, abrasion, chemicals and other environmental factors, reducing surface degradation and maintaining the mechanical and sealing properties.
• Selecting the right material: choosing a rubber compound based on its specific operating environment is essential for long-term performance, with certain materials offering different levels of resistance to water, oils, chemicals, temperature, abrasion and weathering.

Professional guidance from Aquaseal Rubber, expert rubber manufacturers UK and global businesses choose to support their offshore and wind energy projects, can help you extend the service life of your projects safely to enhance operations for long periods of time.

Aquaseal Rubber can support your offshore and wind applications

At Aquaseal Rubber, we understand how important it is to select the right rubber material for your bespoke offshore and wind energy application.

Whether you’re choosing between EPDM or nitrile watertight seals for offshore applications or if you are curious as to why using polyurethane is important in the offshore and wind industry, we are here to help.

Contact us to discuss your requirements and see how we can support your project in the offshore and wind industry.