Blade Root
Repair
Restore damaged blade root inserts onsite, reducing downtime from months to days while avoiding transport, replacement, and factory lead times.
Blade Solution
Blade Root
How It Works Restore the blade root.
Restore the blade root.
Not replace the blade.
Up until now, a wind turbine blade that suffered from loose or damaged bushings either had to be replaced entirely, or the damaged blade needed to be transported to the manufacturer for repair. This resulted in high logistics costs and long downtimes. Today, we can offer a repair solution directly at the wind park site. The blade root is equipped with threaded inserts – also called bushings – that join the rotor blade to the nacelle hub using blade studs.
These inserts can loosen over time. One cause is shrinkage of the polyester if used as resin. This can lead to microcracks, which endangers the bonding between the bushing and the blade and ultimately endangers the structural safety of the blade root. Bonding failure can lead to the loss of a blade and in worst case to a total turbine collapse. Our efficient blade root repair solution, developed together with We4Ce, an international blade rotor and blade root connection expert, allows the repair to be conducted on-site.
Solution Developed in Partnership with We4Ce
To deliver a complete blade root repair solution, CNC Onsite has partnered with We4Ce, an international specialist in blade root connections and rotor blade technology.
While CNC Onsite provides the portable CNC-controlled machining technology used to remove damaged inserts and restore the blade root geometry, We4Ce contributes its expertise in insert design and bonding technology. Together, we have developed a repair process that ensures precise centering, controlled bonding, and reliable long-term structural integrity.
The combination of our precision machining systems and We4Ce's patented Re-FIT bushing technology provides wind turbine operators with a proven alternative to blade replacement, reducing downtime, costs, and unnecessary waste.
Technical Specifications
Typical duration 2–5 days on site
Machining accuracy OEM specification
Surface finish CNC machined contact surface
Certification ISO 9001 | Verified solution
Equipment CNC blade root machining system
Repair scope Bushings, bolts, flange surfaces
Expected lifetime Similar to original
ISO 9001VERIFIED SOLUTIONREUSE OF BLADESREDUCED DOWNTIME
TOTAL ECONOMY Avoid blade transportation, blade replacement, factory repairs, and associated logistics, reducing overall project costs by up to 60%.
REDUCED DOWNTIME On site blade root repairs reduce downtime from months to days by eliminating transport, factory queues, and blade replacement lead times.
Repair Instead of Replace Damaged blade root inserts are restored without replacing the blade, reducing costs and avoiding unnecessary waste.
Structural integrity Combining CNC Onsite's precision machining technology with We4Ce's patented insert and bonding system ensures accurate positioning, reliable bonding, and long-term structural performance
How it works
Our process
01
Quotation request
The wind park contacts us, reporting damage to the threaded bushings in the blade root. We discuss with you the extent of the damage. Determine if further actions are necessary to get the full picture of the damage. Based on the information, we will issue a quotation for the repair work. The wind turbine owner approves the proposal and issues a purchasing order. After that, we can begin the repair within days.
02
Planning
We plan the repairs together with our partner We4Ce. The job is planned in detail with minimal disruption and downtime in mind.
03
Implementation
First, the rotor blade is dismounted and placed in a repair environment within the wind park. The repair area can be created on the ground for onshore wind farms or on the deck of a vessel for offshore wind farms. Once the rotor blade is on the ground and placed in the repair environment, the repair work can start. The portable pre-programmed CNC machine drills away the faulty bushings, matching the precise dimensions of the specialized replacement bushings, developed and patented by We4Ce. New inserts are installed and fixed recreating the bond between the insert and the blade, Upon completion, normally after a few days, the blade can be reinstalled and the turbine can be reinstalled and power production resumed.
04
Handover
When the repairs of the threaded bushings are complete, our technician discusses the final result with the customer, who approves and signs off. We issue a repair report to the customer.
05
Follow-up
As part of CNC Onsite’s high quality standards and professional approach, we offer to follow up on the repair job.
Contact our team Let us find
Let us find
the right solution
Whether it's a repair, machining project, or custom machine solution, our engineers are ready to help you find the most efficient way forward.