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Engineered for Offshore Excellence: LUC Group’s PU Pads for the Skybox Concept

At LUC Group, we take pride in delivering polyurethane solutions that help drive innovation in the offshore energy sector. One of our latest contributions is the specially engineered polyurethane (PU) pad we developed together with Sif for the Skybox concept, to be used on future offshore wind projects.

The Skybox platform connects to a monopile foundation through a conical slipjoint – a clever system where two steel sections fit together, much like stacked coffee cups. While simple in theory, ensuring a secure, durable, and coating-protected connection in harsh offshore environments presents unique challenges.

That’s where our PU pads come in.

The Challenge: Stability, Durability, and Precision

Offshore structures face:

· Extreme loads from wind, waves, and equipment.
· Fabrication tolerances that can affect settlement and stress distribution.
· The need to protect steel coatings over decades of exposure.

Without the right interface material, these factors can lead to uneven load transfer, coating damage, or premature wear, compromising performance and lifespan.

The Solution: High-Performance PU Pads

Through extensive testing and collaboration with Skybox Offshore’s engineers, PU pads with a unique combination of material properties and geometry were developed:

· Material Performance:
Our proprietary polyurethane formulation balances flexibility and stiffness, ensuring strength and long-term durability while still being capable of compensating for fabrication tolerances by compressibility.

· Optimized Geometry:
Pads are designed to deliver:
– Progressive stiffness (softer under light load, firmer as loads increase).
– Even stress distribution to protect coatings and steel.
– Predictable settlement behavior after installation.

· Proven Reliability: The material underwent rigorous testing by an external body for compression strength, friction, and aging under offshore conditions. These results fed into a material model, ensuring the pads meet stringent performance and certification standards.

Why It Matters

By combining cutting-edge polyurethane technology with precision engineering, our PU pads help ensure:

· Stable, predictable Skybox installation and operation.
· Protection of critical steel coatings.
· Durability over the full offshore lifecycle.

Every Skybox platform will integrate these PU pads engineered by Sif and LUC as standard components, supporting the growth of offshore wind infrastructure.

Partnering for the Future of Offshore Energy

With decades of expertise and a global footprint, LUC Group continues to be a trusted partner for offshore energy innovators. From friction pads and rollers to custom moulded components, our polyurethane solutions deliver performance, protection, and reliability in the harshest environments.