Renewable Energy, Solar & Wind Manufacturing worked example

Blade Repair Cost at 61% reworkable defect share: a worked example

This worked example runs the blade repair cost numbers for a tougher week than the baseline: 61% reworkable defect share instead of the typical 85%. Estimates the cost of repairing wind turbine blade composite damage including labor, mobilization and cure.

The inputs for this scenario

  • Repair Labor Hours: 60 hours (held at the documented default)
  • Loaded Labor Rate: 135 $/hr (held at the documented default)
  • Reworkable Defect Share: 61 % (the input this scenario stresses; the baseline uses 85)
  • Mobilization and Cure Cost: 6,500 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total = labor hours x loaded rate x reworkable share% + mobilization and cure cost.
  • Total blade repair cost works out to 11,441 $ at these inputs, and this is the headline figure for the scenario.
  • Blade repair cost per unit works out to 191 $ / piece at these inputs.
  • Variable blade repair cost works out to 4,941 $ at these inputs.
  • Fixed blade repair cost adder works out to 6,500 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where reworkable defect share sits at 85% and the headline result is 13,385 $, this scenario comes in 14.52% below the baseline at 11,441 $.
  • Use it when scoping a composite blade repair campaign, comparing an up-tower rope-access fix against a down-tower or blade-swap option, or building a warranty rework quote. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Total blade repair cost: 11,441 $ (headline result)
  • Blade repair cost per unit: 191 $ / piece
  • Variable blade repair cost: 4,941 $
  • Fixed blade repair cost adder: 6,500 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Blade Repair Cost calculator, set reworkable defect share to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.