Blade tip replacement

TipReplacementComboLightning strikes wreak havoc on wind turbine blades, and sometimes these lightning blasts cause severe damage to the blade tip and lightning protection system. The majority of these damaged blades can be repaired, even if the blade tip is missing. Performance Composites Field Service has the expertise, experience, and equipment to repair or replace the blade tips, and most the time, the repairs can be performed up tower reducing downtime and eliminating crane costs.

On this project, 1.5m (5 ft.) of the blade tip was completely missing, requiring fabrication of new tip shells. Our technicians made splash molds from a good blade of the same series, to create mold surfaces that duplicate the exact shape of the blade tip. We fabricated the new tip shells using equivalent materials, following the laminate sandwich-panel construction of the OEM design and molded under vacuum pressure. The new tip shells were laminated, cured, demolded, trimmed and prepped. We then structurally bonded the new shells to the spar under distributed clamp pressure and also installed new lightning protection components.

Once the new shells were bonded firmly to the spar, at the interfaces of the new shells to the existing shells, we stepped back the layers at the joints and laminated together the inner skins, new core materials, and outer skin laminates. Additional over wrap reinforcement layers were applied to strengthen the leading and trailing edge joints. Finally, all repair surfaces were filled and faired, and two coats of polyurethane paint. This blade had leading-edge protection tape, which was also replaced and edge sealed.

This repaired blade has been operating perfectly since 2014. For more information on repairing lightning damaged blades or to repair badly damaged blades, call or email us.

Why Performance Composites?

  • Expertise
  • Experienced with all major turbines and blade manufacturers
  • Dedicated group of skilled composite engineers and technicians with years of education and hands on blade experience.
  • Specialized on composites repairs. We have experience with all types of damages and we understand the root causes so we will repair the blades properly.
  • Great track record on repairing structural damages including carbon fiber spars and tip replacement.
  • Provide accurate assessment of damages and will advise if the turbine can continue to run and how to monitor the damages.
  • Provide technical support on blade defect negotiation with turbine manufacturers.
  • Investigate serial defects and develop strategy to mitigate the risk and repair the damages.
  • Quality
  • Two year warranty, double the industry standard
  • Every blade repair is performed to OEM standards, following work instructions and using specified materials (no short cuts).
  • Utilize engineering composite standards on structural repairs and follow the specified scarf ratios. Repairs are as strong or stronger than original.
  • Employ state of the art, proprietary Computerized Maintenance Management Software (CMMS) to provide technicians with step by step work instructions, create detailed reports with clear pictures, and provide customer access to the reports via web portal.
  • Reliable
  • Dependable services and long-term partnership
  • Earn the trust of our customers. We take pride in our integrity and always do the right thing. If we make a mistake, we will own it and make it right.
  • A team of safe employees supported by great training and process
  • Continuous communication with site management to ensure effective management of the project.
  • Transparent in all the work we perform and billing we submit.
  • Environmentally conscientious and will clean up after the project so the jobsite is the same or better.
  • Cost-Effective
  • Advocates for owners & operators to reduce costs
  • Reduce turbine downtime by rapid response of crews and repairing damages as quickly as possible.
  • Work with our customers to be proactive and develop great blade maintenance and repair strategy.
  • Work with our customers to schedule inspection and repair during low wind season
  • Reduce mobilization costs by scheduling crews that are located regionally
  • Utilize heated tent enclosures to perform on-ground major blade repairs to reduce delay caused by weather or cold temperatures.
  • Our technicians are available for other on site work to reduce standby costs during bad weather.

Company Information

Performance Composites provides reliable wind turbine blade repair, inspection and consulting services. We are blade and composite experts with a dedicated group of experienced engineers and technicians focused on quality. We are advocates for turbine owners and operators and we will help you develop cost effective solutions to maintain your blades for a 20+ year life.

Contact Information

  This email address is being protected from spambots. You need JavaScript enabled to view it.
  +1 (800) 466-1140
  Physical Address:
1650 Vision St. Suite 245 Abilene, TX 79602
  Mailing Address:
P.O. Box 6225 Abilene, TX 79608