An Innovative Hybrid Structural Retrofit Strategy for Onshore Wind Turbine Repowering

This article proposes and validates a hybrid structural reinforcement strategy for onshore wind turbine foundations in repowering projects, enabling the installation of higher-capacity units without demolishing the existing foundation. In a context of increasing demand for renewable energy and infrastructure optimization, the original foundation is reused as the primary element for global stability and serviceability limit state (SLS) requirements, while ultimate limit state (ULS) demands, arising from the replacement of approximately 1.5 MW turbines with 4.1 MW and 6.25 MW units with power ratings representative of various manufacturers’ models in the current market are resisted by a new peripheral reinforced concrete strengthening system. The study considers both shallow (gravity) and piled foundation typologies, which are the most common globally for wind turbines. This solution, applied to a commercially operating wind farm in southern Brazil with actual load data, demonstrated a substantial reduction in concrete volume–up to 80% for shallow foundations and 40% for piled foundations compared to constructing an entirely new foundation. Structural assessment was performed through numerical modeling in SAP2000, employing a shell-beam hybrid model validated against a 3D solid reference, combined with analytical verifications of limit states. Results confirm that the proposed solution ensures global serviceability and adequate ultimate limit state capacity, achieving significant material optimization. This offers a sustainable and efficient alternative for repowering wind turbine foundations, with notable economic and environmental benefits, including the elimination of demolition, transportation, and material disposal costs.