This paper describes repurposing projects using decommissioned wind turbine blades in bridges conducted under a multinational research project entitled “Re-Wind”. Repurposing is defined by the Re-Wind Network as the re-engineering, redesigning, and remanufacturing of a wind blade that has reached the end of its life on a turbine and taken out of service and then reused as a load-bearing structural element in a new structure (e.g., bridge, transmission pole, sound barrier, seawall, shelter). The issue of end-of-life of wind turbine blades is becoming a significant sustainability concern for wind turbine manufacturers, many of whom have committed to the 2030 or 2040 sustainability goals that include zero-waste for their products. Repurposing is the most sustainable end-of-life solution for wind turbine blades from an environmental, economic, and social perspective. The Network has designed and constructed two full-size pedestrian/cycle bridges—one on a greenway in Cork, Ireland and the other in a quarry in Draperstown, Northern Ireland, UK. The paper describes the design, testing, and construction of the two bridges and provides cost data for the bridges. Two additional bridges that are currently being designed for construction in Atlanta, GA, USA are also described. The paper also presents a step-by-step procedure for designing and building civil structures using decommissioned wind turbine blades. The steps are: project planning and funding, blade sourcing, blade geometric characterization, material testing, structural testing, designing, cost estimating, and construction.

Fiber reinforced polymer (FRP) composite materials have been used in a variety of civil and infrastructure applications since the early1980s, including in wind turbine blades. The world is now confronting the problem of how to dispose of decommissioned blades in an environmentally sustainable manner. One proposed solution is to repurpose the blades for use in new structures. One promising repurposing application is in pedestrian and cycle bridges. This paper reports on the characterization of a 13.4-m long FRP wind blade manufactured by LM Windpower (Kolding, Demark) in 1994. Two blades of this type were used as girders for a pedestrian bridge on a greenway (walking and biking trail) in Cork, Ireland. The as-received geometric, material, and structural properties of the 27 year-old blade were obtained for use in the structural design of the bridge. The material tests included physical (volume fraction and laminate architecture) and mechanical (tension and compression) tests at multiple locations. Full-scale flexural testing of a 4-m long section of the blade between 7 and 11 m from the root of the blade was performed to determine the load-deflection behavior, ultimate capacity, strain history, and failure modes when loaded to failure. Key details of the testing and the results are provided. The results of the testing revealed that the FRP material is still in excellent condition and that the blade has the strength and stiffness in flexure to serve as a girder for the bridge constructed.

High-performance fibre-reinforced concrete (HPFRC), a type of cementitious composite material known for its exceptional mechanical performance, has widespread applications in structures exposed to severe dynamic loading conditions. However, understanding nonlinear HPFRC fracture behaviour, particularly under high strain rates, remains challenging given the complexities of assessment procedures and cost-intensive nature of experiments. This study presents an interpretable framework for modelling and analysing HPFRC fracture strength at high strain rates. A wide range of machine learning methods, including ensemble techniques, were employed to capture multivariate effects of eight essential input features (e.g., mortar compressive strength, fibre physical and mechanical properties, cross-sectional area, and strain rate) on fracture strength response. To assess the derived models, a novel evaluation procedure was proposed involving a data-based analysis, employing established metrics (i.e., coefficient of determination, root mean squared error, and mean absolute error via K-fold cross-validation) and a domain experts-involved evaluation utilising global sensitivity analysis to discern first-order and higher-order interactions among input factors. The proposed approach efficiently yielded both quantitative and qualitative insights into crucial input factors governing HPFRC fracture strength with limited experimental data. The obtained findings highlight the significance of multivariate effects, such as the interaction between strain rate and fibre tensile strength, and between fibre volume and fibre diameter, on fracture behaviour. The proposed interpretable framework aims to provide a powerful tool for proactive material failure analysis by understanding fracture behaviour and identifying potential weak and strong interactions among input factors of HPFRC-based samples. Moreover, the utilisation of the proposed approach enables researchers and civil engineers to efficiently focus on the most critical input parameters during the early design stage and ensuring the structural integrity and safety of HPFRC-based constructions.