Nordex – Corrosion Repair on Wind Turbine Towers, Gibson Bay Wind Farm (South Africa)
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COROSSION
Nordex Energy’s Gibson Bay wind facility
Project Overview: Superior Product Coatings Africa completed a corrosion repair and protective coating application at Nordex Energy’s Gibson Bay wind facility.
The project addressed corrosion deterioration on the tower base flange, door frames, ventilation panels, and associated structural steel components. Environmental exposure, coastal conditions, and moisture retention had resulted in visible rust formation and coating breakdown, particularly around bolted flange connections and access doors.
The objective was to arrest active corrosion, restore structural integrity, and provide a durable protective system capable of withstanding the harsh marine-influenced operating environment.
Challenges and Solutions:
The corrosion repair work at Gibson Bay presented typical wind energy infrastructure challenges, including:
Coastal exposure and salt-laden air
Corrosion around bolted flange connections
Degradation around door frames and ventilation panels
Limited working space around tower base assemblies
Upon inspection, corrosion was evident around the tower base ring, anchor bolt areas, and door perimeters. The solution required complete remediation and encapsulation to prevent further deterioration.
To mitigate further corrosion and extend asset lifespan, Superior Product Coatings Africa implemented a structured repair process which included:
Mechanical surface preparation to remove active corrosion
Cleaning and degreasing of affected substrates
Restoration of compromised areas
Application of a high-performance coating system
Progressive build-up to achieve specified Dry Film Thickness (DFT)
Protective sealing of base flange and bolt assemblies
The coating system was designed to provide long-term corrosion resistance in aggressive coastal conditions while maintaining structural integrity and aesthetic finish.
Performance and Results
Following preparation, the protective system was applied in controlled stages to ensure full encapsulation of the affected substrates.
Final Dry Film Thickness (DFT) readings confirmed compliance with specification, with recorded measurements ranging approximately between 440µm and 768µm, as verified during inspection.
The completed tower demonstrated:
Full corrosion arrest at base flange and door assemblies
Uniform coating coverage across repaired surfaces
Sealed and protected anchor bolt systems
Restored structural and cosmetic integrity
The system now provides a durable barrier against moisture ingress, oxygen exposure, and salt-induced corrosion.
Client Satisfaction
The successful completion of the corrosion repair reinforced Nordex Energy’s confidence in the application methodology and coating performance.
The towers were completed successfully with correct DFTs and in accordance with specification requirements. The project also demonstrated continued improvement in site execution processes and team efficiency.
Collaboration between the SP Coatings Africa team and site representatives ensured safe delivery and effective asset protection.
Conclusion
The Nordex application at Gibson Bay showcases Superior Product Coatings Africa’s capability to deliver high-performance corrosion repair systems within the renewable energy sector.
By restoring compromised steel components and applying a controlled-build protective coating system, the project successfully:
Arrested active corrosion
Protected critical structural connections
Extended the service life of the tower base
Delivered compliant DFT performance
This project confirms SP Coatings Africa’s expertise in corrosion mitigation and long-term protective solutions for wind energy infrastructure operating in harsh environmental conditions.
