Old Wind Turbine Blades Get New Life as Fence Posts

When the first commercial wind farm in Ireland reached the end of its 30-year life this year, its giant blades didn't end up buried in a quarry. Instead, they got a second life as sturdy fence posts and shipping pallets.

Two Northern Ireland companies are tackling a problem most people never think about: what happens to wind turbine blades when they're replaced? The answer has typically been landfills or incineration, neither of which fits the green promise of renewable energy.

Plaswire Ltd in Lurgan is now recycling blades from Bellacorrick wind farm in County Mayo, which was decommissioned at the start of 2024. The company shreds the massive blades and transforms them into a durable material that lasts at least 30 years as fencing or pallets.

The timing couldn't be better. More than 400 turbines across Northern Ireland will need replacing over the next 15 years, creating thousands of tonnes of waste that would otherwise produce enormous carbon emissions through burning.

"We're preventing the incineration of plastics, and burning plastics produces between 2.7 and 2.9 tonnes of CO2 for every tonne burned," said Andrew Billingsley, Plaswire's chief executive. Globally, 125,000 tonnes of blade waste gets disposed of each year, rarely in sustainable ways.

Here's why the old blades need replacing: newer turbines are dramatically more efficient. Bellacorrick's original 21 turbines produced enough power for 4,500 homes. Just 18 new turbines will eventually help power 220,000 homes and businesses when combined with an adjacent wind farm.

The Ripple Effect

Scarva-based company ubloquity adds another innovation to the mix. They attach QR codes to recycled blade products, letting anyone with a smartphone trace the material's complete journey from wind farm to fence post.

"Being able to give a brand and a product a story and a voice on the global stage is totally transformational," said founder Kieran Kelly. Consumers can scan a fence post and learn exactly which turbine blade it came from and when.

This combination of recycling technology and transparency could transform how the renewable energy industry handles its waste. Research from Queen's University Belfast has already proven the material works safely in bridges and street furniture.

The solution keeps plastics out of incinerators, avoids carbon emissions from manufacturing new materials, and extends the environmental benefit of wind turbines long after they stop spinning.