Preprints
https://doi.org/10.5194/wes-2025-56
https://doi.org/10.5194/wes-2025-56
19 May 2025
 | 19 May 2025
Status: this preprint is currently under review for the journal WES.

Feasibility of up-tower repair concepts for pultruded carbon spar cap planks in wind turbine blades

Malo Rosemeier, Matthias Saathoff, Johannes Kolsch, Pablo Buriticá, Enno Petersen, and Christopher Beer

Abstract. While modern wind turbine blades utilize pultruded carbon fiber-reinforced polymer (CFRP) planks for structural integrity in spar caps, these materials can sustain damage from operational stresses, leading to potential failures if unaddressed. Traditional down-tower repairs result in significant costs related to dismantling and transportation, especially for offshore installations, emphasizing the need for efficient up-tower repair methods. The research utilizes a finite element model of an 81.6 m rotor blade designed for a 7 MW offshore turbine, subjected to aeroelastic simulations to evaluate load conditions during maintenance. The analysis focuses on a step-wise increased repair zone, assessing susceptibility to buckling, cyclic strains, and permissible wind speeds. Results indicate that while substantial repairs can endanger structural stability, turbulence-induced strain amplitudes are manageable. Recommendations include installing temporary pretensioning and buckling support structures to enhance safety during repairs. Various innovative support designs are proposed for installation from both inside and outside the blade, aimed at improving structural integrity during up-tower repairs.

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Malo Rosemeier, Matthias Saathoff, Johannes Kolsch, Pablo Buriticá, Enno Petersen, and Christopher Beer

Status: final response (author comments only)

Comment types: AC – author | RC – referee | CC – community | EC – editor | CEC – chief editor | : Report abuse
  • CC1: 'Comment on wes-2025-56', Wolfgang Holstein, 22 May 2025
  • RC1: 'Comment on wes-2025-56', Anonymous Referee #1, 06 Aug 2025
  • RC2: 'Comment on wes-2025-56', Anonymous Referee #2, 14 Aug 2025
Malo Rosemeier, Matthias Saathoff, Johannes Kolsch, Pablo Buriticá, Enno Petersen, and Christopher Beer
Malo Rosemeier, Matthias Saathoff, Johannes Kolsch, Pablo Buriticá, Enno Petersen, and Christopher Beer

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Short summary
This research explores a method for repairing wind turbine blades made from carbon fiber while they remain installed, eliminating costly disassembly. It addresses the challenges of repairing damaged blades and proposes a practical solution to improve repair efficiency. Through structural analysis, we found that this approach can ensure safety during repairs providing significant benefits to the wind energy industry.
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