High-performance repair polymer composites and protective coatings from BELZONA extend the life cycle of wind turbines by repairing erosion and damage instead of replacing entire components, while also reducing carbon emissions.
As the world pushes toward net-zero emissions by 2050, wind and solar energy must dramatically increase their share of electricity generation. With wind power being a key player in this transition, efficient wind farm maintenance is essential to avoid the costly and carbon-intensive replacement of assets. BELZONA offers a crucial, sustainable solution through its advanced polymeric repair composites and protective coatings, which extend the lifespan of wind turbines by repairing key components like blades, nacelles, and towers. This approach reduces carbon emissions, aligns with circular economy principles, as well as helps wind farm operators save significantly on costs.
In a Danish wind farm, 42 turbine blades had severe erosion on the leading edges. Previously, the customer had used pre-formed shells glued to the blades to protect them, but the process was slow and expensive. So, to solve these problems, the client turned to BELZONA's advanced polymer technology:
- BELZONA 5711: a thixotropic paste.
- BELZONA 5721: a high-performance protective coating.
BELZONA 5711 was specially formulated to be used in conjunction with BELZONA 5721 for in-situ repair and reconstruction of leading-edge erosion and impact damage to turbine blades.
“Surface preparation was carried out on each of the 42 blades, followed by the direct application of 90 kg of Belzona 5711 from self-mixing cartridges onto the blade. The repair area was then contoured using a piece of Belzona mixing board. Once cured, a visual inspection was conducted to ensure the application’s readiness for overcoating with 144 kg of Belzona 5721. Using a short-bristled brush, this system was then applied to the leading edge and left to cure for 30 – 60 minutes. With three rope access technicians carrying out the applications, on average, six – nine turbine blades were completed each day,” has stated Morten Sivertsen, General Manager at AESSEAL Danmark A/S.
Benefits of BELZONA’s polymeric technology
- It can be applied in situ without the need for specialised equipment, allowing for rapid repairs, minimising downtime, and avoiding profit losses that come from lengthy turbine inactivity.
- It is faster and more cost-effective than previous methods, allowing the customer to save both time and money.
- Asset owners can significantly extend the lifespan of their wind turbines, avoiding the financial and environmental costs associated with replacing damaged assets. BELZONA plays a vital role in protecting these assets, ensuring the long-term success of the wind power industry and supporting the path to net-zero emissions by 2050.