• Overcoming blades growth limitations
• Robust and reliable solutions: advanced validation strategy
• Representative case studies

As rotor blades continue to scale, current tools face limits. Experts discuss structural challenges, root design issues, and modeling gaps in ultra-large blades.

• Structural mechanics: What we still don’t fully understand and structural modelling limitations for >100m blades
• Growing blades, growing gaps: Scaling effects and hidden loads
• Load assumptions vs. real-world behaviour
• Blade root challenges: Complex stress states and material interfaces
• Scaling effects and unforeseen interaction effects
• Towards better prediction: Needs for validation, testing, and model improvement

As wind turbines increase in age and size, structural issues at the blade root interface — particularly loose or failing bushings — are emerging as a critical reliability concern. This workshop explores a validated onsite blade root repair process and goes further by identifying design lessons that could inform next-generation blade root concepts.

• Root Cause and Onsite Repair Methodology

Failure Diagnostics:

• Systematic Root Cause Analysis: ultrasonic NDT, strength testing, damage patterns
• Common failure modes in root bushings across turbine generations

Validated Repair Approach:

• Application of the Re-FIT bushing and patented Front Infusion Technology (FIT)
• Material interface behavior and bonding strategies

• Design Considerations for Future Blade Roots

Re-thinking the Blade Root Interface:

• Implications of recurring bushing failures for root geometry, materials, and joining concepts
• Opportunities for modular, maintainable, or replaceable root sections
• Designing for maintainability: How to build repairability into future blades

Material & Manufacturing Strategies:

• Lessons from FIT for potential OEM integration in serial blade manufacturing
• Hybrid bonding techniques and localized reinforcement zones

Certification & Testing Needs