The construction and operation of a wind farm requires a large number of technical components that transport the generated electricity safely, ...
Erosion at wind turbines – causes, effects and effective countermeasures
Erosion on rotor blades is one of the underestimated but decisive influencing factors in the operation of a wind turbine. The leading edge of a rotor blade hits rain, hail, sand, salt particles and UV radiation at enormous speed. These stresses have a permanent effect over decades and lead to changes in the surface – both visibly and invisibly. For operators and project planners alike, erosion is therefore not only a technical wear and tear, but a central economic factor that helps determine the yield, maintenance effort and service life of the rotor blades.
Erosion describes the gradual removal of material on the surface, triggered by mechanical and climatic influences. The leading edge is particularly affected, as it experiences the highest direct impact. In addition to rain, hail, sand, salty air, UV radiation and processes of ice formation and thawing also contribute to this erosion. The result is small depressions, roughening and profile changes that intensify over time.
Visible damage to the leading edge is more than an optical problem. Any change in the surface affects the aerodynamics and can lead to measurable performance losses. In practice, plants at locations with high precipitation load or abrasive environments sometimes show significant yield losses if erosion is left untreated. In addition, there are rising maintenance costs, as repairs have to be carried out more frequently. The service life of the rotor blades is also shortened if material removal is combined with cracking, moisture absorption or structural changes.
A systematic inspection is the basis of any successful erosion strategy. Operators use classic visual inspections via rope access as well as modern drone flights with high-resolution cameras. In addition, thermographic tests provide indications of moisture or bond disturbances. Digital image evaluation and AI-supported systems help to classify damage and make developments over time visible. Particularly in locations with high rainfall or sand levels, closer monitoring is worthwhile.
Different approaches are used to counter erosion. Minor damage can be repaired with gelcoat or filler repairs. These methods are straightforward, but often less durable in heavily polluted locations. Modern polyurethane-based leading-edge protective films are much more efficient, as they can be applied quickly, are effective immediately and are particularly suitable for preventive protection. They offer a robust barrier against rain impact, remain UV-stable and enable reproducible quality in the field.
In the case of major damage, a complete reconstruction of the leading edge is necessary. This is time-consuming, more expensive and usually only makes sense if older rotor blades are the focus of a comprehensive repair anyway. In addition, materials are increasingly being tested that are intended to reduce the adhesion of ice. Initial project results show the potential to noticeably shorten winter-related downtimes.
Professional installation is crucial for effective protection. Clean substrate preparation, the right processing temperature and wrinkle- and bubble-free application significantly increase the service life of the film. Equally important is documented tracking to accurately record quality, site conditions, and maintenance cycles. Regular visual inspections ensure that the protective effect is maintained in the long term.
Ideally, erosion control should already be taken into account in the project planning and planning phase – especially in locations with high precipitation intensity, in coastal regions or in areas where abrasive particles occur more frequently in the air. Regular inspections help to detect any damage at an early stage and to initiate appropriate measures. Certified protection systems provide orientation in the selection of suitable solutions and facilitate reliable, long-term planning of operation and maintenance. Since erosion can often cause measurable yield losses after a short time, preventive measures pay for themselves quickly in many cases.
If you would like to check how erosion control can be improved in your specific turbine portfolio or which technical options could be suitable for your rotor blades, you will find more detailed information and expert contacts here. A short exchange is often enough to obtain a well-founded assessment for individual projects.
Against this background, reliable leading edge protection systems are becoming increasingly important. Modern PU protective films – such as those from the RENOLIT product family – are among the established solutions for reducing erosive loads and ensuring the performance of rotor blades in the long term. In cooperation with wind-turbine.com, RENOLIT supports operators and service companies in developing suitable protection concepts for different site conditions.
If you want to assess whether this topic is relevant to your projects or your service portfolio, this can be quickly clarified in a non-binding meeting. Further information – including the possibility to make an appointment – can be found here:
👉 https://corporate-comms.foleon.com/wind-energy/renolit-als-partner/
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