How Engineers Brought Factory-Grade Repairs to the Field
Remanufacturing, the engineering process of restoring worn components to their original specification, has strong potential in wind energy O&M. Blade root inserts are critical load-transfer bushings that have become frequent failure points, presenting as loose bushings, caused by cyclic loading and resin matrix fatigue. Traditionally, on-site repair was impractical, forcing costly transport to OEMs or even blade scrapping. A 2025 case study demonstrated a viable alternative – Dutch We4Ce and Danish CNC Onsite developed a patented remanufacturing method enabling wind park operators to restore inserts on-site. In Europe, technicians were trained in precision drilling, resin infusion bonding, and bushing installation before a dedicated workshop was set up at a 50MW wind park in South Asia. Within weeks, the wind park was carrying out repairs independently. The method delivers up to 60% cost savings, reduces downtime, and eliminates heavy haul logistics. The transferability highlights remanufacturing’s potential as a mainstream O&M strategy, extending rotor blade life while advancing reliability and sustainability goals.
By Søren Kellenberger, CNC Onsite, Denmark and Edo Kuipers, We4Ce, the Netherlands
Loose blade root inserts are a growing issue, requiring corrective repairs within months to avoid fatigue damage and structural failure. Until now, reliable on-site repair was not practicable, forcing costly shipping to manufacturers. This new proven method enables aftermarket on-site remanufacturing, extending blade life at a viable cost.
