Structures and construction methods for repurposing decommissioned wind turbine blades

Abstract

A composite conduit structure for subterranean installation includes a first tubular segment including a cylindrical tubular of a first root section of a first decommissioned wind turbine blade. The first tubular segment has a central axis, a first end, and a second end opposite the first end. In addition, the composite conduit structure includes a second tubular segment including a cylindrical tubular of a second root section of a second decommissioned wind turbine blade. The second tubular segment has a central axis, a first end, and a second end opposite the first end of the second tubular segment. The first tubular segment is coaxially aligned with the second tubular segment. The second end of the first tubular segment is fixably coupled to the first end of the second tubular segment at a fluid tight joint.

Description

STRUCTURES AND CONSTRUCTION METHODS FOR REPURPOSING DECOMMISSIONED WIND TURBINE BLADESCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims benefit of U.S. provisional patent application no. 63 / 650,248 filed May 21 , 2024, and entitled “Repurposing Wind Turbine Blades,” which is hereby incorporated herein by reference in its entirety for all purposes.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not applicable.BACKGROUND

[0003] This disclosure relates generally to structures and construction methods for repurposing of decommissioned wind turbine blades. More particularly, the disclosure relates to civil structures and construction methods for utilizing decommissioned wind turbine blades within civil infrastructures including subterranean conduits, columnar supports, piling supports, and sound barriers.

[0004] Wind turbine decommissioning poses a significant challenge due to the accumulation of large, discarded blades, leading to environmental concerns and inefficient resource utilization. Based on global estimates provided by the Global Wind Energy Council, about 16.8 million tons of fiber-reinforced polymer (FRP) materials will need to be disposed of or recycled by 2030, which is projected to reach nearly 40 million tons by 2050. By 2050, U.S. landfills are expected to see over two million tons of decommissioned wind turbine blades (DWTBs) annually. The conventional practice of recycling wind turbine blades involves shredding the material and attempting to separate reinforcements from the matrix, which is both energy-intensive and environmentally burdensome.

[0005] Certain larger wind turbines, such as three-bladed horizontal-axis wind turbines (HAWTs), have turbine blades coupled to a hub on a horizontally extending main rotor shaft, which transmits wind-derived rotational energy to an electrical generator. The amount of wind energy converted to electrical energy has a positive correlation with blade sizes, such that larger and longer blades are generally more energy efficient. The blades can vary in sizes and materials, but generally include multiple hollow sections orportions to facilitate transportation, enable secure attachment the hub, and improve durability throughout the operational lifetime of the blades.

[0006] For example, as shown in FIG. 1 , an exemplary wind turbine blade 10 is shown. Blade 10 has a longitudinal or central axis 15, a first or proximal end 10a configured to be coupled to a turbine hub, and a second or distal end 10b. In addition, the blade 10 includes a base or root section 20 extending axially from proximal end 10a, a body or midsection 30 extending axially from root section 20, and a cap or tip section 40 extending from midsection 30 to distal end 10b. Thus, the midsection 30 extends axially from the tip section 40 to the root section 20. The root section 20, midsection 30, and tip section 40 collectively define a shell that may be formed of rigid, fiber-reinforced polymer (FRF) materials. The root section 20 includes a cylindrical tubular 21 extending from the proximal end 10aand a transitional, sloped, or tapered portion 24 that expands in size moving axially from the cylindrical tubular 21 to the midsection 30. The midsection 30 extends axially from the root section 20 and has an outer surface with an increased surface area specifically designed to catch wind. The cross-sectional profile of the midsection 30 has an airfoil shape for improved wind capture. As previously described, the tip section 40 extends axially from the midsection 30 to the distal end 10b of the wind turbine blade 10. The particular delineation between the midsection 30 and the tip section 40 can vary based on internal support features within the shell of the wind turbine blade 10 or other structural considerations. In general, the width of the blade 10 is measured perpendicularly to central axis 15. As discussed herein, repurposing of wind turbine blades such as the blade 10 within structural applications leverages the material strength of the blade shells, while increasing resource utilization and decreasing the environmental impact of traditionally discarded blades.BRIEF SUMMARY OF THE DISCLOSURE

[0007] Embodiments of composite conduit structures for subterranean installation are disclosed herein. In one embodiment, a composite conduit structure for subterranean installation comprises a first tubular segment including a cylindrical tubular of a first root section of a first decommissioned wind turbine blade. The first tubular segment has a central axis, a first end, and a second end opposite the first end. In addition, the composite conduit structure comprises a second tubular segment including a cylindrical tubular of a second root section of a second decommissioned wind turbine blade. The second tubular segment has a central axis, a first end, and a second end opposite thefirst end of the second tubular segment. The first tubular segment is coaxially aligned with the second tubular segment. The second end of the first tubular segment is fixably coupled to the first end of the second tubular segment at a fluid tight joint.

[0008] Embodiments of columnar support structures are disclosed herein. In one embodiment, a columnar support structure comprises a plurality of vertically oriented, laterally-spaced columns. Each column has a lower end secured to the ground and an upper end opposite the lower end. Each column comprises a midsection of a decommissioned wind turbine blade. In addition, the columnar support structure comprises a traffic-bearing platform supported above the ground by the plurality of columns. An open face at the upper end of each column is fixably coupled the trafficbearing platform.

[0009] Embodiments of piling support structures are disclosed herein. In one embodiment, a piling support structure comprises a plurality of vertically oriented pile elements. Each pile element comprising a cylindrical tubular of a root section of a decommissioned wind turbine blade. Each pile element has an upper end and a lower end opposite the upper end. The lower end of each pile element comprises an open face disposed within the ground at a depth configured to stabilize the pile element. The upper ends of the plurality of pile elements are coplanar with one another to establish a pile foundation for supporting an above-ground structure.

[0010] Embodiments of sound barrier structures are disclosed herein. In one embodiment, a sound barrier structure comprises a foundation element comprising a solid material defining a rectilinear slot therein. In addition, the sound barrier structure comprises a plurality of horizontally adjacent, vertically oriented baffles retained within the rectilinear slot and in contact with one another. Each baffle comprises a midsection of a decommissioned wind turbine blade.

[0011] Embodiments described herein comprise a combination of features and characteristics intended to address various shortcomings associated with certain prior devices, systems, and methods. The foregoing has outlined rather broadly the features and technical characteristics of the disclosed embodiments in order that the detailed description that follows may be better understood. The various characteristics and features described above, as well as others, will be readily apparent to those skilled in the art upon reading the following detailed description, and by referring to the accompanying drawings. It should be appreciated that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designingother structures for carrying out the same purposes as the disclosed embodiments. It should also be realized that such equivalent constructions do not depart from the spirit and scope of the principles disclosed herein.BRIEF DESCRIPTION OF THE DRAWINGS

[0012] For a detailed description of various exemplary embodiments, reference will now be made to the accompanying drawings in which:

[0013] FIG. 1 is a perspective view of a wind turbine blade;

[0014] FIG. 2 is a side exploded view of an embodiment of a composite conduit structure formed from a plurality of aligned root sections of decommissioned wind turbine blades in accordance with the principles described herein;

[0015] FIG. 3 is a side view of the composite conduit structure of FIG. 2;

[0016] FIG. 4 is a perspective view of an embodiment of a pipe culvert system including a plurality of pipe culverts made of the composite conduit structures of FIG. 3 in accordance with the principles described herein;

[0017] FIG. 5 is a perspective end view of an embodiment of a subterranean pedestrian underpass made of the composite conduit structure of FIG. 3 in accordance with the principles described herein;

[0018] FIG. 6 is a perspective view of an embodiment of a columnar support structure formed from a plurality of midsections of decommissioned wind turbine blades utilized as roadway bridge pier columns in accordance with the principles described herein;

[0019] FIG. 7 is a perspective view of an embodiment of a columnar support structure formed from a plurality of midsections of decommissioned wind turbine blades utilized as coastal bridge columns in accordance with the principles described herein;

[0020] FIG. 8 is a perspective view of an embodiment of a columnar support structure formed from a plurality of midsections of decommissioned wind turbine blades utilized as coastal pier columns in accordance with the principles described herein;

[0021] FIG. 9 is a side view of an embodiment of a piling support structure formed from a plurality of root sections of decommissioned wind turbine blades utilized as cylindrical pipe piles for supporting an above-ground structure in accordance with the principles described herein; and

[0022] FIG. 10 is a perspective view of an embodiment of a vertical barrier structure formed from a plurality of midsections of decommissioned wind turbine blades in accordance with the principles described herein.DETAILED DESCRIPTION

[0023] The following discussion is directed to various exemplary embodiments. However, one skilled in the art will understand that the examples disclosed herein have broad application, and that the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment.

[0024] Certain terms are used throughout the following description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not function. The drawing figures are not necessarily to scale. Certain features and components herein may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in interest of clarity and conciseness.

[0025] Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints, and open-ended ranges should be interpreted to include only commercially practical values. In addition, with respect to all ranges disclosed herein, such ranges are intended to include any combination of the mentioned upper and lower limits even if the particular combination is not specifically listed. All lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary. Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11 , 0.12, 0.13, etc.).

[0026] In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to... .” Use of broader terms such as comprises, includes, having, etc. should be understood to provide support for narrower terms such as consisting of, consisting essentially of, comprised substantially of, etc. Use of the term "optionally" with respect to any element of a claim is intended to mean that the subject element is required, or alternatively, is not required. Both alternatives are intended to be within the scope of the claim.

[0027] The term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct engagement between the two devices, or through an indirect connection that is established via other devices, components, nodes, and connections. In addition, as used herein, the terms “axial” and “axially” generally mean along or parallel to a particular axis (e.g., central axis of a body or a port), while the terms “radial” and “radially” generally mean perpendicular to a particular axis. For instance, an axial distance refers to a distance measured along or parallel to the axis, and a radial distance means a distance measured perpendicular to the axis. As used herein, the terms “approximately,” “about,” “substantially,” and the like mean within 10% (i.e., plus or minus 10%) of the recited value. Thus, for example, a recited angle of “about 80 degrees” refers to an angle ranging from 72 degrees to 88 degrees.

[0028] As will be understood, the civil structures and methods described herein provide multiple benefits that solve issues associated with the end-of-life management for decommissioned wind turbine blades or DWTBs. With the wind energy sector maturing and decommissioning an increasing number of wind turbine blades worldwide, there is a correspondingly increasing demand for innovative and sustainable methods to repurpose the composite materials of the blades. As such, the systematic repurposing of decommissioned wind turbine blades for civil infrastructure presents significant improvements to the environmental challenges associated with retiring wind turbine blades formed of composite materials, such as fiber-reinforced polymer (FRP).

[0029] Departing from more traditional, energy-intensive recycling methods, the present disclosure provides a systematic approach for directly integrating entire sections of decommissioned wind turbine blades into various civil infrastructure projects. Current recycling practices, involving the separation of materials, are associated with high energy consumption and environmental impact. The present embodiments mitigate these issues by repurposing the entire composite structure of decommissioned wind turbine blades as structural components for various civil infrastructure projects. In particular, the direct integration of shell material of decommissioned wind turbine blades minimizes energy-intensive recycling processes and capitalize on the inherent strength and durability of the blades. The present disclosure therefore extends the lifespan of these materials while also offering a sustainable alternative with reduced carbon emissions and efficient resource utilization.

[0030] Moreover, the structural reutilization of wind turbine blades disclosed herein provides circular and sustainable processes for adapting the pre-constructed structural integrity and strength of wind turbine blades for large-scale applications. Embodiments disclosed herein include civil infrastructure structures such as composite conduit structures (e.g., pipe culverts, pedestrian underpasses), columnar support structures (e.g., roadway bridge pier columns, coastal bridge columns, coastal pier columns), piling support structures (e.g., circular pipe pile foundations), and vertical barrier structures (e.g., roadway sound barriers, standing sea walls).

[0031] These applications further reduce material use and costs by replacing more traditional concrete or steel pipes, columns, or structures produced for individual, specific uses. Moreover, unlike existing technologies that may have limited applications, this approach demonstrates the versatility of repurposed decommissioned wind turbine blades in various civil infrastructure projects. The adaptability to the various structures disclosed herein highlight the reusability for wind turbine blades to address diverse engineering needs, providing more flexible and widely applicable structural components. Accordingly, and as will be described in more detail below, embodiments described herein are directed to civil structures and construction methods apparatus for repurposing decommissioned wind turbine blades (in whole or part) as composite conduit structures, columnar support structures, piling support structures, and vertical barrier structures.

[0032] As described above, FIG. 1 illustrates an exemplary wind turbine blade 1 Concluding a root section 20, a midsection 30, and a tip section 40. The root section 20 is designed to fixably couple the wind turbine blade 10 to the main hub of a wind turbine for capturing wind energy. The root section 20 is a tubular having a generally annular cross-sectional profile, while the midsection 30 has an airfoil-shaped crosssection. The wind turbine blade 10 generally increases in width moving axially from each end 10a, 10b toward a middle portion. For example, the width of the blade 10 increases moving along central axis 15 from a distal end 10a to the point of maximum width, and the width also increases moving axially from proximal end 10a toward the maximum width. In general, the wind turbine blade 10 can have a significant overall axial length measured between ends 10a, 10b, such as 50 ft, 100 ft, 150 ft, 200 ft, or more. Additionally, the tubular root section 20 may have an inner diameter of 5 ft or more (e.g., 6 ft, 7 ft, 8 ft, 9 ft, 10 ft, or more).

[0033] In embodiments, the shell of the wind turbine blade 10 is made a durable composite material, such as glass-fiber-reinforced polymers (GFRP) or carbon-fiber- reinforced polymers (CFRP). As detailed above, the present disclosure leverages the decommissioning of wind turbine blades for second-life applications within civil infrastructure, which utilize all or specially prepared sections of the shells for structural supports.

[0034] The following figures provide details for repurposing decommissioned wind turbine blades into: composite conduit structures such as pipe culverts or pedestrian underpasses; columnar support structures such as roadway bridge pier columns, coastal bridge columns, or coastal pier columns; piling support structures such as pipe pile foundations; and vertical barrier structures such as roadway sound barriers or sea walls. In general, each decommissioned wind turbine blade 10 can be cut to a predetermined, desired length to form individual sections suitable for low cost transportation and on-site construction of civil structures.

[0035] Referring now to FIGS. 2 and 3, a composite conduit structure 60 formed from a plurality of root sections 20 of decommissioned wind turbine blades is shown. The composite conduit structure 60 is an elongate tubular having a central or longitudinal axis 80 and an inner throughbore or path 61 extending axially therethrough. In general, the composite conduit structure 60 can be employed in an suitable civil and / or structural applications. As shown in FIG. 2, a plurality of tubular segments 70, 72, 74, which have been repurposed from root sections 20 of decommissioned wind turbine blades 10, are coaxially aligned and fixably coupled end-to-end to form the composite conduit structure 60. For example, each tubular segment 70, 72, 74 may be cut and formed from a root section 20 of a decommissioned wind turbine blade 10 (e.g., tubular segment 70 may be formed from the cylindrical tubular 21 of the root section 20 of a first decommissioned wind turbine blade 10, tubular segment 72 may be formed from a the cylindrical tubular 21 of the root section 20 of a second decommissioned wind turbine blade 10, and tubular segment 74 may be formed from the cylindrical tubular 21 of the root section 20 of a third decommissioned wind turbine blade 10).

[0036] Each tubular segment 70, 72, 74 includes strong, durable, and weather-resistant walls of composite materials, based on maintaining the structural integrity of the decommissioned wind turbine blades 10 from which they are repurposed. Moreover, the unassembled composite conduit structure 60 (FIG. 2) may include any suitable number of tubular segments 70, 72, 74, such as 1 , 2, 3, 4, 5, 10, 15, 20, or more, coaxiallyaligned and arranged in series to produce composite conduit structure 60 of any desired length. Any two or more of the tubular segments 70, 72, 74 may have the same length or different lengths specifically selected for particular application.

[0037] Each tubular segment 70, 72, 74 has a longitudinal or central axis 75, a first end 70a, 72a, 74a, respectively, and a second end 70b, 72b, 74b, respectively, opposite the first end 70a, 72a, 74a, respectively. The tubular segments 70, 72, 74 are arranged in series with the central axes 75 coaxially aligned generally along the longitudinal axis 80. As such, the first end 70a of the first tubular segment 70 is facing outward or away from the other tubular segments 72, 74, the second end 70b of the first tubular segment 70 is axially adjacent the first end 72a of the second tubular segment 72, the second end 72b of the second tubular segment 72 is axially adjacent the first end 74a of the third tubular segment 74, and the second end 74 of the third tubular segment 74 faces away from the other tubular segments 70, 72. The axially adjacent ends of tubular segments 70, 72, 74 are fixably coupled together to form the composite conduit structure 60.

[0038] As a non-limiting example of assembling the composite conduit structure 60, select ends of the tubular segments 70, 72, 74 may be flared so as to have an enlarged inner diameter sized and configured to receive a mating end of the axially adjacent tubular segment 70, 72, 74. For example, the second end of the first tubular segment 70 may be flared to slidingly receive the first end 72a of the second tubular segment 72 and form an overlapping joint therebetween, and the second end 72b of the second tubular segment 72 may be flared to slidingly receive the first end 74a of the third tubular segment 74 to form an overlapping joint therebetween. Such overlapping joints can be relied on to form an annular waterproof connection between adjacent tubular segments 70, 72, 74.

[0039] As shown in FIG. 3, the composite conduit structure 60is an elongated waterproof tubular structure that can be used as a conduit, pipe, or tube configured for subterranean installation. The connections between adjacent tubular segments 70, 72, 74 are preferably waterproof and fluid tight joints or connections 84 that enable the composite conduit structure 60 to be installed underground or in another environment that receives moisture, without permitting external fluid to permeate the composite conduit structure 60 or permit fluids within the composite conduit structure 60 from exiting into the environment surrounding structure 60. In some embodiments, the waterproof connections 84 utilize a pipe fitting such as a collar or coupling formed of a suitable watertight material (e.g., metal, fiber-reinforced polymer composite, plastic) toprotect and seal the boundary between adjacent tubular segments. In addition or alternative to a pipe fitting, the waterproof connections 84 may be protected and sealed with an adhesive or gap-filling material, including epoxy, marine sealant, concrete, expanding foam, and so forth.

[0040] As previously described, the composite conduit structure 60 can be used in a variety of applications. For example, referring now to FIG. 4, a plurality of the composite conduit structures 60 are utilized within a pipe culvert system 100. The illustrated embodiment of the pipe culvert system 100 includes a roadway 102 underneath which three composite conduit structures 60 are installed or embedded as pipe culverts 104. Each pipe culvert 104 is a composite conduit structure 60 as previously described, which may be formed from one or more tubular segments 70, 72, 74 that are repurposed from root sections 20 of decommissioned wind turbine blades 10 and connected end-to-end in series to a desired overall length, as discussed above. Thus, the pipe culverts 104 include walls formed of waterproof composite material derived directly from the root sections 20 of the decommissioned wind turbine blades 10. Based on their structural strength and rigidity, the pipe culverts 104 provide suitable channels defined by the throughbores 61 for fluid 106 such as water to flow underneath the roadway 102. The specialized repurposing of the root sections 20 of decommissioned wind turbine blades 10 as pipe culverts 104 can therefore replace a significant number of traditional pipe culverts made from reinforced concrete, sheet metal, or weaker plastic materials. The relative thinness of the walls of the pipe culverts 104 produced as composite conduit structures 62 can further reduce construction constraints by enabling subterranean tunnels of reduced diameters to provide the same fluid flow as a traditional culvert.

[0041] As another example, as shown in FIG. 5, a composite conduit structure 60 is utilized within a pedestrian underpass system 150. The pedestrian underpass system 150 extends through a physical obstruction, structure, or formation 152 such as a bridge, an overpass, a roadway, or another large-scale land feature through or past which individuals may desire to travel. The composite conduit structure 60 is installed or embedded through the formation 152 as a pedestrian underpass crossing 154 that enables pedestrians, cyclers, or other individual travelers to easily traverse through the formation 152. It should be appreciated that the root sections 20 of many decommissioned wind turbine blades 10 have inner diameters that exceed the heightof travelers, thereby facilitating the direct implementation of the composite conduit structure 60 made of the root sections 20 to allow travelers to traverse therethrough.

[0042] As described above, the composite conduit structure 60 can include any suitable number of tubular segments 70, 72, 74 interconnected end-to-end in series to establish a generally waterproof tunnel or passage. The illustrated embodiment includes a first tubular segment 70 fixably coupled to a second tubular segment 72 to provide the pedestrian underpass crossing 154 with a length equal to or greater than a length underneath the formation 152.

[0043] Additional civil structures disclosed herein may implement one or more portions of a decommissioned wind turbine blades 10 as vertically extending columnar support structures. For example, the midsections 30 and / or the root sections 20 of decommissioned wind turbine blades 10 can be repurposed as columnar support structures within an inland roadway bridge, a coastal roadway bridge, or a coastal pier, as illustrated in FIGS. 6, 7, and 8, respectively. In certain embodiments, the generally cylindrical root sections 20 are utilized for columnar supports in high-force applications having an increased load per columnar support. Moreover, the more planar, airfoilshaped midsections 30 may be utilized in lower-force applications, such as in structures where the columns are provided in greater numbers and / or support a lower load. It should also be understood that certain embodiments may include a combination of root section-based columns and midsection-based columns, dependent on the particular force analysis for a civil structure.

[0044] Referring now to FIG. 6, an embodiment of a columnar support structure 200 having columnar supports or columns 202 formed from decommissioned wind turbine blades 10 is shown. Each column 202 is formed from the midsection 30 of a decommissioned wind turbine blade 10 . That is, the columnar support structure 200 is made from a plurality of midsections 30 of repurposed wind turbine blades 10 replaces conventional concrete columns . The columns 202 are secured to or positioned within the ground to support a traffic-bearing roadway 204 above a ground surface. A direction of traffic 206 is defined along the roadway 204, and the roadway 204 may include any suitable arrangement of girders or beams to more evenly distribute operational forces between the roadway 204 and the columns 202. In certain embodiments, the columns 202 of the columnar support structure 200 are laterally spaced along a lateral axis 210 extending generally perpendicular to the direction of traffic 206.

[0045] Each column 202 includes a vertically oriented central or longitudinal axis 220, a lower end 222, and an upper end 224 opposite the lower end 222. In some embodiments, the lower end 222 of each column 202 includes an open face that is driven into the ground to a depth sufficient to support the column 202 and portion of the weight of the roadway 204 (and any other strucutres) supported by the column 202. The lower ends 222 may be stabilized additionally or alternatively by construction techniques including the addition of concrete for stability. In some embodiments, the upper end 224 of each column 202 includes an open face that is secured orfixably coupled to a bottom surface of the roadway 204 (or girder or beam supporting the roadway 204). In general, such attachments may be any suitable brackets and / or fasteners known in the art, such as L-shaped brackets that transfer force between an outer edge of the column 202 and a corresponding portion of the bottom surface of a laterally-extending or transverse girder of the roadway 204.

[0046] As the columns 202 are formed from the midsections 30 of wind turbine blades 10, each column 202 includes a shell with an airfoil-shaped outer boundary defined by a first edge (e.g., leading or trailing edge), a second edge (e.g., corresponding trailing or leading edge), and a pair of sides extending between the edges. The columns 202 may rotationally oriented about axes 220 in any direction that increases support provided to the roadway 204 and / or reduces wind-based interference. For example, the sides of each column 202 may be aligned to be generally parallel with the direction of traffic 206 on the roadway 204 and / or wind.

[0047] Although illustrated with four columns 202, it should be understood that any suitable number and / or arrangement of columns 202 may be provided to support the roadway 204, such as two columns, three columns, or more arranged along the lateral axis 210 perpendicular to the direction of traffic 206. Arrangements with three or more columns 202 may further distribute force by including a first column positioned underneath a first lateral side of the roadway 204, a second column positioned underneath a second lateral side of the roadway 204, and one or more middle columns laterally positioned between the first column and the second column underneath a middle portion of the roadway 204.

[0048] Referring now to FIG. 7, another embodiment of a columnar support structure 250 is shown. Columnar support structure 250 includes a plurality of vertically oriented columns 252 that function as coastal bridge columns within a coastal zone. Each column 252 is made of the cylindrical tubular 21 of one or more of the root sections 20of decommissioned wind turbine blade(s) 10. For example, a plurality of the cylindrical tubulars 21 may be coupled together end-to-end as previously described with respect to composite conduit structure 60 to form a pile element 352. In other embodiments, all or a portion of each column 252 may be formed from the midsection 30 of a decommissioned wind turbine blade 10.

[0049] The columnar support structure 250 includes the columns 252 arranged in laterally extending rows generally parallel to a lateral axis 254, extending transverse to a direction of traffic 256 on a traffic-bearing platform or roadway 260 supported by the columns 252. For example, the illustrated embodiment includes a first plurality of columns 252 arranged in a laterally extending row underneath the roadway 260 and a second plurality of columns 252 arranged in a laterally extending row underneath the roadway 260.

[0050] The lower end of each column 252 may be open so as to be more efficiently driven into the coast or sand to reach a stabilizing depth. The columns 252 formed from the repurposed decommissioned wind turbine blades may beneficially substitute more expensive, heavy, and resource-intensive concrete columns traditionally used for roadway bridges.

[0051] Referring now to FIG. 8, a perspective view of another embodiment of a columnar support structure 300 is shown. In this embodiment, the columnar support structure 300 includes a plurality of columns 302 supporting a coastal pier 304. The coastal pier 304 is a traffic-bearing platform that may facilitate foot traffic to and from a distal end 310 of the coastal pier 304. Each column 302 is formed from the midsection 30 of a repurposed decommissioned wind turbine blade 10. In embodiments, the columns 302 for supporting the coastal pier 304 are arranged in laterally spaced pairs along a length of the coastal pier 304 defined along a direction of traffic 312.

[0052] Referring now to FIG. 9, a side view an embodiment of a foundation or piling support structure 350 is shown. Piling support structure 350 includes a plurality of pile elements 352 driven into the ground for supporting an above-ground structure. In this embodiment, each pile element 352 is made from one or more cylindrical tubular(s) 21 of the root section(s) 20 of repurposed decommissioned wind turbine blade(s) 10. For example, a plurality of the cylindrical tubulars 21 may be coupled together end-to- end as previously described with respect to composite conduit structure 60 to form a pile element 352. In other embodiments, each pile element 352 may be made from themidsection 30 of a repurposed decommissioned wind turbine blade 10. The pile elements 352 can generally replace traditional circular pipe piles formed of steel and offer enhanced corrosion resistance.

[0053] In the illustrated embodiment, the piling support structure 350 includes the pile elements 352 disposed within the ground 354, such as sand, dirt, and / or soil, to a depth 356 sufficient to stabilize the pile elements 352 and any superstructure to be disposed thereon. As examples, an above-ground structure or superstructure including a building, a house, a bridge, or a pier can be constructed on the piling support structure 350, which establishes a relatively long-lasting and highly durable structural foundation.

[0054] Each pile element 352 has a vertically oriented central or longitudinal axis 360, an upper end, and a lower end opposite the upper end relative to the vertical axis 360. In some embodiments, the lower end of each pile element 352 may include an open face in fluid communication with the hollow volume within a main body of the pile element 352 to facilitate installation. For example, the pile elements 352 may be installed by being driven and / or rotated downward with a waterjet positioned inside the hollow volume. In certain embodiments, the pile elements 352 are installed at the desired depth 356 by heavy machinery that drills or defines an opening within the ground surface 354 to receive the pile elements 352. Dependent on the end use, the pile elements 352 may each be filled with sand, concrete, or another stabilizing material.

[0055] In certain embodiments, the upper end of each pile element 352 is coplanar or generally coplanar with other pile elements 352 to establish the desired pile foundation. In this embodiment, each pile element 352 has substantially the same vertical height when installed. The pile elements 352 may be arranged in a contiguous, rectangular arrangement, in a spaced, polygon-shaped array, or in any suitable shape or array that provides suitable piling support.

[0056] Referring now to FIG. 10, a perspective view of an embodiment of a vertical barrier structure 400 is shown. The vertical barrier structure 400 includes a continuous or interconnected line of elongated baffles 402 supported at their base by a foundation 404. Each baffle 402 is formed from the midsection 30 and / or the tip section 40 of a decommissioned wind turbine blade 10. For example, the tip section 40 of the wind turbine blade 10 may be retained with all or a portion of the midsection 30 for embodiments in which capping or closure of an upper end of the baffle 402 is desired. In embodiments employing midsections 30 without the tip sections 40, a hollow spacewithin each baffle 402 may be fully or partially filled with a filler material such as concrete, soil, or sand.

[0057] In embodiments, the vertical barrier structure 400 is implemented as a sound barrier structure, such as a wall that is positioned alongside a roadway to dampen vehicular noise emitted from the roadway. The vertical barrier structure 400 of certain embodiments can be implemented as an above-ground sea wall for reducing the spread of waves. Additional embodiments may include utilizing the vertical barrier structure 400 as a protective fencing for blocking passage across an area. As such, the vertical barrier structure 400 includes versatile applications that leverage the structural integrity and durability of the wind turbine blade midsections and / or tip sections from which it is constructed.

[0058] In some embodiments, the foundation element 404 supporting the baffles 402 is formed of a solid material, such as concrete, and includes a rectilinear slot extending parallel to a longitudinal axis 406. The baffles 402 may be retained and / or affixed within the rectilinear slot while maintaining contact with one another to form a continuous vertical barrier.

[0059] A length of the vertical barrier structure 400 may be increased or maximized by aligning a horizontal axis of each baffle 402 along with the longitudinal axis 406. As detailed above, the baffles 402 constructed by repurposing particular sections of wind turbine blades 10 may include an airfoil-shaped cross-section. The airfoil-shaped crosssection of each baffle 402 generally includes an outer boundary defined by a relatively wide leading edge, a relatively thin trailing edge, and a pair of sides extending between the edges. In some embodiments, horizontally adjacent baffles 402 may be arranged such that the leading edge of a first baffle is in contact with the leading edge of a second adjacent baffle and the trailing edge of the second baffle is in contact with the trailing edge of a third baffle.

[0060] With the above description of various example embodiments in mind, the present disclosure provides a comprehensive system and methodology for the strategic repurposing of decommissioned wind turbine blades for the development and construction of various civil infrastructure projects or structures. The structures and methods disclosed herein enable the efficient utilization of either individual sections or entire units of decommissioned wind turbine blades, with a primary emphasis on minimizing reprocessing energy while preserving their inherent structural integrity. By repurposing wind turbine blades for second-use applications, the technologycontributes to the reduction of waste generated by decommissioned blades and enhances the overall sustainability of the wind energy sector.

[0061] Furthermore, the disclosed technology is supported by comprehensive structural testing and demonstrates the feasibility of repurposing decommissioned wind turbine blades in various civil engineering applications. Through structural testing on tip sections, midsections, and root sections of decommissioned wind turbine blades, supported by finite element modeling (FEM), the innovation informs subsequent design, fabrication, and construction process. To ensure the viability and safety of repurposed decommissioned wind turbine blades, the disclosure involves a rigorous process of structural testing, focusing on tip sections, midsections, and root sections of the blades. Through the generation of a finite element model, a thorough analysis, informing the subsequent design, fabrication, and construction phases is conducted. In certain embodiments, one or more suitable sensors are integrated within the civil structures, enabling real-time measurement of deformation, vibration, and behavior of structure. This feature facilitates ongoing demonstration and durability studies, allowing for a comprehensive assessment of the repurposed decommissioned wind turbine blades' performance in a practical setting.

[0062] As described above, the embodiments disclosed herein address environmental concerns associated with the disposal of decommissioned wind turbine blades, provide an energy-efficient alternative to traditional recycling practices, and promote the structural reutilization of decommissioned wind turbine blades in civil infrastructure projects, thereby contributing to the advancement of sustainable and circular practices in the wind energy sector. By combining structural testing, finite element modeling, and practical construction, the embodiments disclosed herein highlight various applications for the responsible and innovative repurposing of decommissioned wind turbine blades, addressing both environmental and infrastructural challenges.

[0063] While preferred embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teachings herein. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the systems, apparatus, and processes described herein are possible and are within the scope of the disclosure. For example, the relative dimensions of various parts, the materials from which the various parts are made, and other parameters can be varied. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims thatfollow, the scope of which shall include all equivalents of the subject matter of the claims. Unless expressly stated otherwise, the steps in a method claim may be performed in any order. The recitation of identifiers such as (a), (b), (c) or (1 ), (2), (3) before steps in a method claim are not intended to and do not specify a particular order to the steps, but rather are used to simplify subsequent reference to such steps.

[0064] Each and every claim is incorporated into the specification as an aspect of the present disclosure. Thus, the claims are a further description and are an addition to the aspects of the present disclosure. The discussion of a reference herein is not an admission that it is prior art to the presently disclosed subject matter, especially any reference that may have a publication date after the priority date of this application. The disclosures of all patents, patent applications, and publications cited herein are hereby incorporated by reference, to the extent that they provide exemplary, procedural or other details supplementary to those set forth herein. In the event of conflict, the present specification, including definitions, is intended to control.

Claims

CLAIMSWhat is claimed is:

1. A composite conduit structure for subterranean installation, the composite conduit structure comprising: a first tubular segment comprising a cylindrical tubular of a first root section of a first decommissioned wind turbine blade, wherein the first tubular segment has a central axis, a first end, and a second end opposite the first end; and a second tubular segment comprising a cylindrical tubular of a second root section of a second decommissioned wind turbine blade, wherein the second tubular segment has a central axis, a first end, and a second end opposite the first end of the second tubular segment; wherein the first tubular segment is coaxially aligned with the second tubular segment, and wherein the second end of the first tubular segment is fixably coupled to the first end of the second tubular segment at a fluid tight joint.

2. The composite conduit structure of claim 1 , wherein the composite conduit structure defines a pipe culvert or a pedestrian underpass crossing.

3. The structure of one of claim 1 or 2, wherein the first end of the second tubular segment is received by the second end of the first tubular segment.

4. The structure of claim 3, wherein the second end of the first tubular segment is flared such that an outer diameter of the second end of the first tubular segment is greater than an outer diameter of the first end of the second tubular segment.

5. The structure of any of claims 1-5, wherein the secondend of the first tubular segment and the first end of the second tubular segment are coupled via a pipe fitting, an adhesive, or both.

6. The structure of one of claims 1 -6, wherein the first decommissioned wind turbine blade and the second decommissioned wind turbine blade comprise walls made of a composite material including a glass-fiber-reinforced polymer or a carbon-fiber- reinforced polymer.

7. The structure of any of claims 1-6, comprising a third tubular segment that comprises a cylindrical tubular of a third root section of a third decommissioned wind turbine blade, wherein the third tubular segment has a central axis, a first end, and a second end opposite the first end of the third tubular segment, and wherein the second end of the second tubular segment is fixably coupled to the first end of the third tubular segment at a fluid tight joint.

8. A columnar support structure, comprising: a plurality of vertically oriented, laterally-spaced columns, wherein each column has a lower end secured to the ground and an upper end opposite the lower end, and wherein each column comprises a midsection of a decommissioned wind turbine blade; and a traffic-bearing platform supported above the ground by the plurality of columns, wherein an open face at the upper end of each column is fixably coupled the traffic-bearing platform.

9. The columnar support structure of claim 8, wherein each column includes a shell with an airfoil-shaped outer boundary defined by a first edge, a second edge, and a pair of sides extending from the first edge to the second edge, and wherein of the pair of sides of each column are oriented generally parallel to a direction of traffic on the trafficbearing platform.

10. The columnar support structure of claim 8 or 9, wherein an open face at the lower end of each column is driven into the ground to a depth configured to stabilize the corresponding column.

11. The columnar support structure of any of claims 8-10, wherein the plurality of columns comprises:a first plurality of columns positioned underneath a first lateral side of the trafficbearing platform; and a second plurality of columns positioned underneath a second lateral side of the traffic-bearing platform.

12. The columnar support structure of any of claims 8-11 , wherein the plurality of columns comprises at least three columns arranged in a line extending perpendicular to a direction of traffic on the traffic-bearing platform.

13. The columnar support structure of claim 12, wherein the at least columns comprise: a first column positioned underneath a first lateral side of the traffic-bearing platform; a second column positioned underneath a second lateral side of the trafficbearing platform; and one or more columns laterally positioned between the first column and the second column underneath a middle portion of the traffic-bearing platform.

14. The columnar support structure of any of claims 8-13, wherein the traffic trafficbearing platform comprises an inland roadway bridge, a coastal roadway bridge, or a coastal pier.

15. A piling support structure, comprising: a plurality of vertically oriented pile elements, wherein each pile element comprising a cylindrical tubular of a root section of a decommissioned wind turbine blade, wherein each pile element has an upper end and a lower end opposite the upper end, wherein the lower end of each pile element comprises an open face disposed within the ground at a depth configured to stabilize the pile element, and wherein the upper ends of the plurality of pile elements are coplanar with one another to establish a pile foundation for supporting an above-ground structure.

16. The piling support structure of claim 15, wherein each pile element of the plurality of pile elements includes a same vertical height defined along their respective vertical axes.

17. The piling support structure of claim 15 or 16, wherein the plurality of pile elements is positioned in a rectangular arrangement.

18. A sound barrier structure, comprising: a foundation element comprising a solid material defining a rectilinear slot therein; and a plurality of horizontally adjacent, vertically oriented baffles retained within the rectilinear slot and in contact with one another, wherein each baffle comprises a midsection of a decommissioned wind turbine blade.

19. The sound barrier structure of claim 18, wherein each baffle has a airfoil-shaped cross-section defined by a leading edge, a trailing edge, and a pair of sides extending from the leading edge to the trailing edge, and wherein the leading edges of a first pair of adjacent baffles contact each other and the trailing edges of a second pair of adjacent baffles contact each other.

20. The sound barrier structure of claim 18 or 19, wherein the sound barrier structure is configured to be positioned adjacent a roadway to dampen noise therefrom.

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