U.S. wind turbine blade repairs exceed $1 billion in 2025
Credit: Published 10/03/2025 · Grace Nehls · compositesworld.com ~~
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As recently reported by market research and business strategy consulting firm InstelStore (Houston, Texas, U.S.), in 2025 the industry is poised to spend more than $2.92 billion on wind turbine repairs in the U.S. Blades contribute the most at 37%, and now total more than $1 billion in annual cost. Within that category, lightning damage is the largest cost center, with more than $255.7 million in repairs being undertaken in 2025. This is expected to escalate to more than $333 million by the end of 2034.
Blade root failures are now the second most expensive repair for wind turbines, with more than $222.3 million in annual costs, InstelStore finds. Root insert separation is a well-known issue on certain makes and models of wind turbines, and is contributing to the cost spike for blades due to the requirement to call out a large crane for safety to remove and replace a blade with such damage.
Pitch bearing repairs are the next most expensive category, with more than $190.9 million. Despite the fact that up-tower repairs can be made with segmented components, some machines do not have a crane-less solution for certain repairs, particularly when a full bearing swap is required.
https://www.wind-watch.org/news/2025/10/04/u-s-wind-turbine-blade-repairs-exceed-1-billion-in-2025/
