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Circular Wind Turbines?

After about 25 years of generating electricity, a wind turbine must be dismantled and its parts recycled. Most of the parts in the wind turbines motor and tower can be recycled, but the blades, made of fiberglass, is another matter. A startup recently founded by Aalto University alumni is one company now trying to address this problem.

The wind turbine blades are made from fiberglass bound together with epoxy resin, a material so strong it is incredibly difficult and expensive to break down. Most blades end their lives in landfill or are incinerated. Blade waste is projected to reach 43 million tons globally by 2050.

Current options are not only wasteful but have environmental drawbacks. Incineration brings pollution and, while wind companies say there is no toxicity issue with landfilling blades, this is not totally clear.

A study from 2024, published in ASCE Journal of Construction Engineering and Management, propose “/…repurposing wind turbine blades as the primary load-carrying elements for high-voltage transmission line structures…/” could be a solution from both an environmental and financial point of view. “Under this case study, our results show that BladePoles have lower greenhouse gas emissions than steel poles, and we anticipate BladePoles will be less costly than steel poles.” 

Still, the blades eventually end up as landfill…

Veolia, a resource management company headquartered in France, turns old blades into an ingredient for cement production. It shreds, sorts and blends blade materials before sending them to cement kilns. Using this blend reduces the planet-heating pollution produced in cement manufacturing by 27%, according to Veolia. The program has processed 2,600 blades so far.

The REWIND Project studies new technologies for dismantling wind turbine blades and to introduce new ways of repurposing and recycling composite materials. The overall goal is to improve the circularity of these materials, increase their industrial applications, and minimise reliance on landfilling and incineration.

Reverlast 

A company founded by Aalto University alumni, is rewriting the narrative by transforming these discarded blades into robust, floating structures capable of withstanding even the harshest marine conditions.

The company’s debut project is Aalto University’s new community sauna, set to float gracefully on pontoons crafted from repurposed turbine blades. With final tests planned before the holidays, the sauna is anticipated to open next spring, offering an inspiring example of innovation, sustainability, and community engagement.

Rethinking Fiberglass Waste

Metals such as aluminium, steel, and copper from the towers and motors are nearly 100% recyclable. However, recycling the fiberglass blades has proven far more complex.

In Finland, burying blades in landfills is prohibited, a policy that will soon extend across Europe under an upcoming EU directive. The most common current method—crushing blades for use in cement production—has significant drawbacks. While it reduces emissions in cement manufacturing, the energy-intensive crushing process and subsequent combustion release carbon dioxide.

Reverlast, however, sees these blades as an opportunity rather than a challenge.

Turning Blades into Floating Innovation

“Wind turbine blades are made of the same high-performance material as boats, designed to endure marine environments for decades,” explains Reverlast CEO Johannes Peace, an Aalto University alumnus with a background in bio- and chemical engineering. Peace, a passionate sailor, first noticed this potential three years ago while on the water.

Partnering with fellow alumnus Ossi Heiskala, a graduate of Aalto’s School of Business, the pair developed a business model focused on upcycling blades into sustainable floating docks and pontoons. These innovative structures replace traditional materials like concrete and polyethylene plastic, significantly reducing environmental impact.

“Our prototype dock prevents roughly 2.6 tons of carbon dioxide emissions,” notes Heiskala. “The larger and more numerous our docks, the greater the impact.”

A Community-Driven Sauna

Reverlast’s inaugural project, the floating sauna, highlights their vision. The sauna itself is a classic wood-heated barrel sauna, but its foundation—a floating dock supported by pontoons crafted from four wind turbine blades—embodies cutting-edge sustainability. The fiberglass pontoons are exceptionally strong, with a thickness of up to 6 centimeters, compared to the typical 1 centimeter in sailboats.

“This pontoon is built to last,” says Heiskala. “Our challenge is ensuring all components meet the same durability standard.”

The project has drawn enthusiastic support from the Aalto community. Sustainability Action Booster funding has covered material costs, while student volunteers from the Polytechnical Sauna Society and Aalto Sustainability Club have contributed their time and expertise.

For Martina Presepi, Chair of the Aalto Sustainability Club, the project represents the best of Finnish culture and innovation. “I’ve loved saunas since moving to Finland, and this one is special—not only because it’s floating but because it’s rooted in sustainability and creativity. It will be a gathering place for thousands of students and a symbol of what we can achieve together.”

The Bigger Picture

While Finland’s wind turbine fleet is still relatively young, only 10–20 blades are dismantled annually. However, this number will grow significantly in the coming decade, driving demand for innovative recycling solutions.

Reverlast is ready. Beyond floating docks, the company envisions using blade tips for lighter structures like swimming platforms and sturdier blade sections for larger projects, such as breakwaters.

“The more we innovate, the more we can maximize the potential of these materials,” says Heiskala.

As the floating sauna nears completion, its creators hope it will serve as both a welcoming space and a powerful example of sustainable design. If successful, this bold initiative could inspire similar projects worldwide, turning a global recycling challenge into a blueprint for innovation.

For more information: Aalto University

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