Smulders and ARGON strengthen offshore wind competitiveness through integrated shopfloor metrology

Precision, speed and risk reduction in serial transition piece manufacturing

As offshore wind structures continue to grow in scale and complexity, manufacturers are under increasing pressure to deliver (sub)millimeter accuracy at industrial speed. In this context, Belgian offshore foundation specialist Smulders Projects has partnered with ARGON Measuring Solutions to structurally embed advanced Shopfloor Measurement Solutions (SMS) into its production of transition pieces in Hoboken, Belgium.

By integrating ARGON’s FLANGEscan and WELDscan systems within a broader automated metrology framework, Smulders has fundamentally redefined the role of measurement. What was once a final verification step has evolved into a core production function, driving accuracy, improving throughput, enhancing safety, and reducing risk.

Metrology as a production enabler

Offshore wind manufacturing is entering a new phase of industrialization. With monopiles exceeding 10 meters in diameter and hub heights approaching 150 meters, geometric control has become a decisive factor not only for quality, but also for cost, safety and long-term performance.

Smulders moved away from fragmented measurement tools toward a fully integrated and scalable metrology strategy embedded directly into production.

In this environment, even the smallest deviations can have significant consequences. A few tenths of a millimeter may already affect offshore installation or structural integrity over time. Traditional measurement approaches, often reliant on manual processes and operator expertise, struggle to keep pace with quality and time demands. They introduce variability, extend cycle times and increase the risk of costly rework.

Bart Mariën, General Manager Supporting Services at Smulders in Hoboken: "Recognizing this shift, Smulders moved away from fragmented measurement tools toward a fully integrated and scalable metrology strategy embedded directly into production."

From standalone tools to integrated systems

To turn this into reality, Smulders started collaborating with ARGON, a partner that goes beyond supplying measurement equipment. ARGON introduced a complete Shopfloor Measurement Solution in which hardware, software and process are tightly interconnected. A high-precision laser tracker is combined with robust metrology software, proprietary tooling and application-driven workflows that guide operators step by step.

For Smulders, ease of use is essential. At the core of the approach lies in the straightforward 'Coffee Machine Principle': advanced metrology should be as easy to use as a coffee machine. Operators follow intuitive, template-based instructions, while complex measurement logic runs in the background.

Bart Mariën explains: "After a rapid adoption, Smulders established consistent execution regardless of operator experience, effectively eliminating variability between shifts and teams, and realizing immediate operational impact."

Operators follow intuitive, template-based instructions, while complex measurement logic runs in the background.

FLANGEscan: faster, safer and fully traceable

Flange geometry plays a critical role in offshore wind structures, where alignment during installation must be exact. Deviations in flatness, tilt or ovality can quickly escalate into costly offshore corrections. With the introduction of FLANGEscan, Smulders is theoretically able to accelerate its measurement process 4 to 5 fold.

The ARGON system captures a far greater volume of data, enabling objective validation and full traceability of every flange.

"When taking various organizational constraints into account, Smulders increases measurement efficiency 50%, while improving accuracy and safety," says Mariën. "Non-contact measurement has largely replaced manual work at height, reducing risk for operators. At the same time, the system captures a far greater volume of data, enabling objective validation and full traceability of every flange."

Measurement takes place faster and has become a reliable quality filter, removing subjectivity and providing documented evidence that strengthens confidence toward clients, contractors and certification bodies.

WELDscan: preventing errors before they occur

While FLANGEscan optimizes validation, ARGON WELDscan brings measurement directly into the production process itself. The system guides operators in marking and verifying secondary welding elements through intuitive, tablet-based workflows. Based on the acquired measurement data, the digital reports are generated.

Mariën explains: "The accurate reports offer Smulders 100% confidence in what has been measured accurately and efficiently. Standardized digital reporting also ensures consistency, traceability and compliance with increasingly stringent offshore certification requirements."

What previously required time-consuming manual activities using a roller tape, can now be executed quickly and consistently guided by a laser tracker. Mariën: Deviations can be detected immediately after tack welding. This fundamentally changes the role of measurement, from detecting errors to preventing them. For large welded structures, where rework can be extremely costly, this shift has a direct and measurable impact on profitability and planning reliability. Again, Smulders realizes impressive measurement efficiency gains through weld scanning, in this case amounting up to 4-fold."

Smulders realizes impressive measurement efficiency gains through weld scanning, in this case amounting up to 4-fold.

Integrated measurement for predictable production

Embedding measurement into production enables continuous verification at key stages instead of only end-of-line inspection. This provides intermediate feedback, shortens decision loops, and reduces variability, making production more predictable and first-time-right.

Mariën concludes: "Here at Smulders, the integrated ARGON solution has shortened measurement cycles, improved accuracy and repeatability, and reduced dependence on specialized expertise. Through safer conditions and faster feedback, we are able to further streamline operational efficiency, while automated shopfloor metrology helps stabilize production, lower non-quality costs, and scale manufacturing economically."

A strategic shift in offshore wind manufacturing

As offshore wind scales in Europe and globally, manufacturers require precise and predictable processes in response to tighter deadlines, larger components, and shrinking margins.

“ARGON helped us move from 'measuring to verify' to 'measuring to create value,'" says Mariën. "Integrating metrology into production is a strategic choice, driving efficiency, quality, and competitiveness. Data-driven and operator-friendly measurement now supports Smulders' offshore wind manufacturing, successfully combining precision, speed, and reliability."

The collaboration between Smulders and ARGON illustrates a broader industry shift: measurement is no longer an end-of-line task but a core part of product engineering, manufacturing, and validation.

Measurement is no longer an end-of-line task but a core part of product engineering, manufacturing, and validation