From Blade to Barrier
The embodiment design of a noise barrier from horizontally oriented, decommissioned wind turbine blades
S.M.O. Ornstein (TU Delft - Industrial Design Engineering)
J.J. Joustra – Mentor (TU Delft - Design for Sustainability)
G. Nijenhuis – Mentor (TU Delft - Materializing Futures)
M.J.A. van Amstel – Mentor (Heijmans Infra)
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Abstract
This thesis proposes a design with the reuse of decommissioned wind turbine blades (WTBs) as structural elements in highway noise barriers. While wind energy continues to grow rapidly, the decommissioning of turbines is generating a large and increasing stream of composite blade waste. This waste is difficult to recycle and often disposed through environmentally harmful methods such as landfilling or incineration. At the same time, WTBs still possess valuable mechanical properties that make them suitable for structural reuse applications.
The research develops and tests a modular noise barrier concept in which 12-meter blade segments are horizontally placed into U-shaped steel frames. The design takes advantage of the natural blade curvature to improve acoustic performance, while focusing on ease of assembly, durability, safety standards and drainage. Key features include capped and sealed segment ends, anti-graffiti coatings, acoustic cover strips, and integrated emergency exits.
The resulting concept demonstrates that WTBs can be repurposed into feasible, scalable, and structurally reliable noise barriers. The design offers a circular way for storing composite material until advanced recycling technologies become more widely available to reuse it, while it acts as a functional noise barrier. While further development is required in areas such as logistics, cost, and market acceptance, this thesis highlights the potential of structural reuse to extend the material life of blades and contribute to more sustainable infrastructure projects.