Wind energy is a key driver in the global shift toward renewable power. In recent years, the onshore wind sector has experienced strong growth in the demand for reliable andefficient construction solutions.
Wind energy is generated by converting the kinetic energy of moving air into electricity using wind turbines. These turbines must withstand not only static loads but also dynamic forces caused by the rotation of the blades. Additionally, they operate in some of the harshest and most isolated environments on the planet.
To maximize the efficiency and reliability of wind turbines, Sika has developed a comprehensive portfolio of solutions for wind power construction. With deep expertise in construction technologies, Sika offers a complete suite of products and services for windenergy projects – from the foundation of the wind tower to the blades of the turbine.
CHALLENGES IN ONSHOREWIND FARMS
Achieving reliable load transfer: Onshore wind turbines face extreme static and dynamic forces, combined with challenging environmental conditions. Ensuring that towers remain stable under these stresses is a major challenge, especially as turbines grow taller and more powerful. Reliable load transfer from the tower to the foundation is critical to prevent structural failures and maintain safe operations.
Durability and long-term performance: Wind turbine foundations and tower components are constantly exposed to harsh environmental conditions, including moisture, temperature fluctuations, and chemical agents. Over time, these factors can degrade materials, corrode reinforcement, and weaken the structural integrity of the wind farm. Maintaining longterm durability under such conditions is a critical challenge for onshore wind energy projects.
Operational efficiency and lifecycle management: Managing the ongoing operation of wind turbines over decades presents significant challenges. Damage to foundations due to dynamic loads and settlement, and unexpected component failures can impact energy production, safety, and overall efficiency. Ensuring reliable performance throughout the turbine’s lifecycle requires careful planning and proactive management of longterm operational risks.
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Ultra-high performance grouts for towers
AS ONSHORE WIND TURBINES grow taller and more powerful, the demands placed on their foundations continue to rise.
Robust grout is the critical link between the wind turbine tower and its foundation. It ensures reliable load transfer, absorbs extreme static and dynamic forces, and provides the long-term stability every wind farm depends on. Understand that, we proudly offer ulta-high performance grouting solutions for wind energy.
BENEFITS OF SIKA SOLUTIONS
Ultra-high performance grouting solutions include:
SikaGrout®-9110/9130/9140
Ultra-high strength, fatigue resistant cement-based grout for onshore wind turbines with steel towers
SikaGrout®-9320 BE
Ultra-high strength, fatigue resistant cement-based grout designed for steel & hybrid towers with reduced CO2 footprint
SikaGrout®-295
High performance, cementitious grout for onshore wind turbines with concrete towers
Sikadur®
Epoxy adhesives for precast segment bonding
- High compressive strength
- Early strength development
- High flow
- High fatigue resistance
- Certified by OEMs
- High application thickness
- For every wind turbine design
- Long service life
- Different packages
- Easy to apply
- Pumpable to high locations
Tailor made solutions for concrete towers
Sika offers comprehensive systems for durable, sustainable, and high performing concrete towers. Engineered to withstand harsh climates and dynamic loads while enabling greater hub heights and optimized long-term strength.
Sika solutions include:
SikaGrout®-9320 BE
Ultra-high strength, fatigue resistant cement-based grout designed for steel & hybrid towers with reduced CO2 footprint
SikaGrout®-295
Ultra-high strength, fatigue resistant cement-based grout designed for steel & hybrid towers with reduced CO2 footprint
Sikadur®
Epoxy adhesives for precast segment bonding
Sikagard®
Silane-based corrosion inhibitors and water repellents
Sikagard®-550 W Elastic/5500/300
1 component, plasto-elastic coating based on UV-curing acrylic dispersion with excellent crack-bridging properties even at temperatures below 0 °C. Complying with the requirements of EN 1504-2 asprotective coating
Concrete towers
Maintenance, repair & lifecycle extension
Extending the service life of wind turbines is essential as renewable energy demand grows. Foundations face weather, dynamic loads, and long-term wear, making proactive maintenance key to preserving structural integrity and minimizing downtime. By protecting foundations early and effectively, operators reduce repair needs, lower lifecycle costs, and keep energy production running smoothly. With Sika’s proven solutions for protection and repair, wind farms can operate safely, reliably, and sustainably for many years.
Sika solutions include:
Onshore wind turbine foundations endure extreme environmental conditions and continuous mechanical loads throughout their lifespan. Over time, these factors can lead to structural deterioration, including cracking in concrete, corrosion of reinforcement, and overall weakening of foundation components. If left unaddressed, these issues can compromise structural integrity and safety, potentially reducing the turbine’s operational efficiency and lifespan. Therefore, timely damage assessment and repair are essential to maintaining the foundation’s strength and reliability.
Sika solutions include:
Sika MonoTop® và SikaEmaco®
1-component, fiber-reinforced, low shrinkage structural repair mortars forre-profiling damaged concrete and restoring structural integrity
Sikadur®
2-component, epoxy-based adhesives to ensure structural bonding during repair
Sikadur® và SikaInject®
2-component, epoxy- and PU-based injection resins to structurally repair cracks
Sikacrete®-560
Prepackaged, quick setting mortar suitable for repairing application by dry spray methods
Waterproofing is essential to ensuring the longevity, durability, and structural integrity of onshore wind turbine foundations. Exposure to moisture, freeze-thaw cycles, and harsh environmental conditions can lead to concrete deterioration, reinforcement corrosion, and costly repairs. By implementing advanced waterproofing solutions, wind farm operators can proactively prevent water infiltration, protect against chemical and mechanical damage, and enhance the resilience of turbine foundations, ultimately reducing maintenance needs and maximizing operational efficiency.
Sika waterproofing solutions include:
Sikalastic®
High-performance, liquid-applied polyurethane or cementitious waterproofing membranes
Sikaflex®
Moisture-curing, elastic polyurethane sealants
Steel reinforcement is the backbone of wind turbine foundations and precast towerelements, but it is also highly vulnerable to corrosion caused by carbonation, chloride ingress, and moisture penetration. Once corrosion sets in, it can rapidly compromise structural integrity, safety, and service life, leading to costly repairsor even premature failure. Proactive corrosion protection is therefore critical in extending the lifespan of wind energy infrastructure, ensuring that turbines continue to performreliably in demanding onshore environments.
Sika corrosion protection solutions include:
Sikagard®
Silane-based corrosion inhibitors and water repellents
Sikagard®-550 WElastic/5500/300
Lớp phủ đàn hồi dẻo 1 thành phần, dựa trên chất phân tán acrylic đóng rắn bằng tia UV, có đặc tính che phủ vết nứt tuyệt vời ngay cả ở nhiệt độ dưới 0 °C. Đáp ứng các yêu cầu của tiêu chuẩn EN 1504-2 đối với lớp phủ bảo vệ
With the growing demand for renewable energy, extending the service life of existing wind turbines has become more important than ever. Full replacements are costly and resource-intensive, while strengthening existing foundations offers a sustainable, economical, and efficient way to ensure continued reliability and safety. By reinforcing foundations, operators can maintain performance, adapt to higher loads, and support the transition toward a cleaner energy future.
SIKA SOLUTIONS INCLUDE:
Sika® CarboDur®
Carbon fiber plates for structural strengthening
SikaWrap®
Carbon fiber fabric for structural strengthening
SikaDur®
2-component epoxy adhesives for structural strengthening
Maintenance, repair & lifecycle extension
Advanced admixtures for precast segments & foundations
Precast concrete elements play a crucial role in the construction of concrete and hybrid wind turbine towers as well as their foundations, offering precision, efficiency, and durability.
However, to meet the demanding conditions of wind energy infrastructure, advanced concrete admixtures are essential in optimizing the performance of these precast components. By improving workability, strength development, and durability, admixtures enable superior crack resistance, reduced shrinkage, and enhanced load-bearing capacity, ensuring the long-term stability of wind turbine structures.
SIKA SOLUTIONS INCLUDE:
Sika® ViscoCrete®
Superplasticizer to improve workability and increase strength and durability of high performance concrete
SikaPump®
Pumping agent to enhance pumpability and reduce pumping pressure, especially in case of difficult mix designs and unfavourable grading curves
Sika® ViscoFlow®
Superplasticizer for production of mass concrete and realization of extended workability times
SikaFume®
Additive based on silica fume to enhance durability
SikaFiber®
Micro- and macrofibers for enhanced durability and reinforcing of concrete
