During the repowering of Endesa’s wind farm in Aldeavieja, Ávila, a structural concrete that incorporates recycled fibers from wind turbine blades has been applied for the first time in Europe. These blades, traditionally discarded in landfills due to their material complexity, have been transformed into a new type of aggregate through a crushing and reformulation process.
From Old Turbines to Green Concrete
The project was developed within the framework of the European Blades2Build initiative, which brings together fourteen strategic partners, including Endesa and Holcim. In the intervention, 22 obsolete turbines were replaced by 4 new generation wind turbines, increasing the installed capacity from 14.5 MW to 24 MW. All of this under a zero-waste approach: dismantled elements were recycled, resold as spare parts, or integrated into new infrastructures.
Holcim, through its Innovation Center in Lyon and its laboratory in Alcobendas, has led the formulation of the new concrete. This material was developed using ECOCycle technology, allowing the replacement of part of the natural aggregate with fibers from dismantled blades. This advancement is part of the ECOPact line, which promotes sustainable materials with a lower environmental footprint in construction.
Circular economy with concrete made from recycled wind turbine blades at the Aldeavieja wind farm. Source: Holcim
Aldeavieja Leads the Reuse of Wind Turbine Blades
The experience in Aldeavieja is considered pioneering in the transition towards a more sustainable model for wind infrastructure management. The reuse of composite fibers avoids the extraction of raw materials, reduces emissions, and minimizes transport logistics. This model is expected to be scaled up in other repowering operations.
The project received a grant of 6.51 million euros from the Institute for Diversification and Energy Saving (IDAE), as part of the “Circular Repowering” program financed by the European Union’s Recovery, Transformation and Resilience Plan. Operational tests of the wind farm are scheduled for October 2025.
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Source and photo: Endesa
