Nexans High-Voltage Subsea Cables, Manufacturing Facility
Nexans needed to expand its manufacturing capabilities to meet growing demand for offshore wind infrastructure while maintaining ongoing operations at its existing high-voltage cable facility. The project transformed the active plant into a hybrid manufacturing environment capable of producing both land-based and subsea high-voltage cables without disrupting production.
Designing for Continuous Cable Production
The shift to submarine cable manufacturing introduced entirely new operational requirements. Unlike land-based cable produced in shorter segments, offshore wind installations require continuous cable lengths extending for kilometers to reduce the need for offshore splices — one of the highest-risk points in long-term high-voltage cable performance.
Nexans manufacturing facility was redesigned around the movement and protection of continuous cable runs throughout the manufacturing process. Elevated cableways, roller systems, and specialized routing infrastructure guide massive lengths of cable through the plant while maintaining strict performance and handling requirements.
The resulting environment supports precision manufacturing at an industrial scale, carefully coordinating equipment, circulation, and cable movement throughout the facility.
Phased Construction in an Active Manufacturing Environment
Construction and renovations occurred while the facility remained fully operational. This required detailed phasing strategies and close coordination with ongoing manufacturing activities.
The project team worked alongside plant operations to minimize disruption, maintain safety, and support uninterrupted production throughout implementation.
Understanding industrial workflows and equipment sequencing was critical to integrating new systems within the active facility.
Flexible Manufacturing for a Changing Energy Market
As offshore wind market conditions evolved, the facility’s adaptable design allowed Nexans to retain and later reintegrate long-length land cable production alongside subsea manufacturing operations.
The project demonstrates how flexible industrial environments can help manufacturers respond to changing market demands while protecting long-term operational value.
Learn More
- Watch this video about the transformed high voltage subsea cable plant.
- Also, see more advanced manufacturing projects.