As the world experiences the effects of ecological transition, the production of alternative renewable and sustainable energy is becoming increasingly important – with wind power playing a vital role.
According to the GWEC’s (Global Wind Energy Council) Market Intelligence team, the wind industry continues to set new annual installation records and will continue to do so in the coming years, according to its forecasts. A total of 23,098 wind turbines were installed worldwide in 2024 by 29 different wind turbine manufacturers - made up of 18 from Asia Pacific, 8 from Europe, 2 from America and 1 from Middle East. The wind industry continues to set new annual installation records and will continue to do so in the coming years, according to GWEC forecasts.*
Harnessing power from the wind is one of the cleanest and most sustainable methods to generate electricity. In response, Mapei has developed a complete solution, from cathodic protection to concrete restoration. The system includes grouts, admixtures, waterproofing, pure zinc anodes, mortars, hydrophobising products and epoxy resins - which have been extensively researched to develop low carbon formulas whilst increasing product performance, with carbon offsetting of residual carbon - for new installations and the restoration of existing wind towers.
Anchoring of the turbine
High performance grout plays a crucial role in the installation process, to anchor steel constructions and seal joints within concrete and hybrid installations. The Mapegrout WT range includes three fluid cementitious grouts which provide exceptional resistance to dynamic stress and rapid development of mechanical properties. Extended workability and ease of pumping also provide benefits during installation and across long distances.
Waterproofing foundation structures
Predetermined durability is essential in wind power plants, with waterproofing of the basement playing a key role. Here, Mapei Purtop 200 two-component waterproof membrane and Aquaflex S 1K liquid waterproofing protect concrete from the ingress of aggressive agents, whilst withstanding stresses in increasingly extreme weather conditions.
Protecting reinforcement rods
The lifespan of concrete structures is affected by the corrosion status of reinforcement bars. To slow down or prevent the corrosive process, Mapei has developed a specific galvanic cathodic protection system – Mapeshield. Suitable for new and existing structures, the system features pure zinc anodes and multilayer pure zinc anodes which are coupled with a special paste. The anodes can be monitored with a Mapeshield Monitoring Box and, for ease of specification, cathodic protection systems can be sized with the Mapeshield Software Design online calculation tool.
Admixtures for low carbon concrete
The use of new mineral additions to reduce clinker content in cement production is a key environmental strategy in reducing CO2 emissions and achieving Carbon Neutrality. However, the new mixtures present several challenges, including increased water demand. In response, Mapei has developed Cube System - a portfolio of solutions for low carbon concrete production. Cube System optimises clinker hydration and the reactivity of mineral additions, ensuring high standard concrete production, whilst reducing environmental impact.
Concrete maintenance with CO2-offset mortars
To restore and maintain the concrete foundations of existing wind towers, Mapei offers a range of repair mortars, with CO2 Fully Offset in the Entire Life Cycle. Formulated to increase dynamic flexural strength characteristics, the mortars offer high resistance to cracking and cyclical loads, with low environmental impact. Products include quick-setting Planitop Smooth & Repair R4 Zero cementitious mortar and fibre-reinforced formulations, Mapegrout Easy Flow Zero and Mapegrout Hi-Flow Zero.
Impregnating hydrophobising solutions
Water and humidity can trigger degradation in concrete wind towers. To inhibit water ingress into the concrete mix, Mapei has developed Planiseal WR – a complete range of silane-based impregnating hydrophobising products. The impregnators penetrate deep into the substrate, without affecting the concrete’s finish or breathability, reducing water/chloride ingress and preventing deterioration caused by freeze-thaw cycles. They can be used to protect below ground and exposed surfaces.
Solution to cracking phenomena
Concrete structures often suffer from cracking phenomena and restoration is essential to restore performance. Epojet pure epoxy resin completes the Mapei system, sealing both localised and diffuse cracks, promoting mechanical strength and providing high water resistance.
To find out more about Mapei solutions for onshore wind turbines ➜
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