HAIZEEKO project studies coatings, smart monitoring and eco-design for offshore wind structures

Source | Cidetec Surface Engineering

Private applied research organization Cidetec Surface Engineering (Gipuzkoa, Spain) is participating in the HAIZEEKO project to develop innovative alternative technologies — such as coatings, more eco-friendly designs and monitoring systems — to enable more efficient, sustainable and competitive offshore wind systems, with a primary focus on blades and towers.

Offshore wind structures are constantly exposed to extreme environmental conditions, which demands increasingly effective protection solutions. To address this reality, systems are used that combine active and passive methods adapted to the materials employed and the specific environment. This need for protection also influences the design and manufacture of blades, which incorporate new materials to improve their efficiency and sustainability. However, major challenges remain in terms of recyclability and structural resistance.

In addition, conventional metallic coatings present significant limitations: They do not exceed 25 years of service life without requiring costly periodic maintenance. They also generate leachates and volatile organic compounds (VOCs) that pollute both the atmosphere and the marine environment. To prevent galvanic corrosion, sacrificial anodes are used, adding complexity and additional maintenance costs to this infrastructure.

The HAIZEEKO project is addressing three technological axes:

Sustainability through the development of recyclable materials for blades and ceramic corrosion protection CX coatings for support structures that ensure the service life demanded by operators.
Energy efficiency through eco‑design and aerodynamic improvements to blades that can be transferred to real applications, with implicit operational advantages.
Improved durability for blades and structures, aiming at minimal maintenance costs in offshore operation, reinforced by research into disruptive monitoring EA technologies as preventive maintenance.

To achieve these objectives, three lines of research have been defined. The first focuses on advanced protection methods, such as inert ceramic coatings with anti‑icing properties and a novel hybrid laser‑and‑induction vitrification technology. The second addresses eco‑design and the use of more sustainable materials, including dynamic 3R epoxy resins (reprocessable, repairable and recyclable) and removable adhesives that facilitate repair and recycling. The third line focuses on monitoring systems, with ultrasonic control techniques for ceramic coatings and optimized filtering systems for detection under real service conditions.

The project consortium is formed by Navacel (coordinator); Argolabe Ingeniería; Mecanizados Ekimen; Global Factor; Innomat Coatings; Innovation Tree; Manutención y Manipulación Eraman; Kera‑Coat and Mandiola Composites. The HAIZEEKO project includes the participation of Cidetec Surface Engineering and Tecnalia as RVCTI agents, with the collaboration of the Basquenergy Cluster.

The project will run for 3 years (2025–2027) and is funded by the Department of Industry, Energy Transition and Sustainability of the Basque Government (HAZITEK Programme) and the European Regional Development Fund (ERDF).