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Case Studies

Here are a few of our success stories. With a track record spanning over 500 projects, we have a wealth of experience in enhancing asset performance. These examples showcase the impact of our dedicated approach.

Blade Repair and Maintenance at Mt Gellibrand Wind Farm

Client: Acciona
Location: Mt Gellibrand Wind Farm, VIC
Task: Leading Edge (LE) Refurbishment (All WTGs) & Repair of Structural Defects
Turbines: 44 Nordex Acciona Windpower AW125/3000

Direct Wind Services was engaged by Acciona to deliver a comprehensive refurbishment of all wind turbine blades at the Mt Gellibrand Wind Farm. In addition to the planned works, our team also undertook structural composite repairs to defects identified during routine inspections conducted while on site.
Scope of work included:

  • Full assessment, composite repairs, and application of a Leading-Edge Protection (LEP) system across all 132 turbine blades.
  • Structural repairs to a variety of blade defects discovered through operational and routine inspection processes.
  • Use of multiple height access methods, including Rope Access (RA) and Elevated Work Platforms (EWP), to ensure a strategic balance between quality, safety, and efficiency.
  • End-to-end project management, encompassing planning, procurement, implementation, and final closeout.

The project was successfully delivered on schedule and within budget, resulting in a measurable improvement in aerodynamic performance and a notable reduction in leading-edge erosion rates. These enhancements significantly improved turbine reliability and operational efficiency, reinforcing Direct Wind Services’ position as a leader in blade care and life extension solutions.

Multibrand Service Support at Sites in South Australia

Client: Vestas
Location: South Australia
Task: Service support for high-torquing of turbine towers, main frames and blades, Bolt Tensioning & Routine Servicing

Our technicians provided specialist support including:

  • High-torquing of turbine towers, main frames and blade bolts
  • Provided direct support and autonomy to achieve the 3-month preventative maintenance service to be completed within schedule.

The augmentation of technical staff enabled Vestas to accelerate their maintenance timeline while upholding the highest safety and performance standards. Our seamless integration into the OEM’s operations was a testament to our flexibility and professionalism.

Large-Scale Bulkhead Repairs at Waubra Wind Farm

Client: Acciona
Location: Waubra Wind & Gunning Wind Farms, VIC & NSW
Task: Blade Bulkhead Repairs on 168 blades

Our services included:

  • Damage Assessment and Reporting
  • Removal and replacement of degraded blade bulkhead components and materials
  • Manufacture of structural reinforcement components in our Australian facilities.
  • Implementation & installation of structural reinforcement materials to the blade bulkheads

All 168 blades were successfully refurbished with a zero-incident safety record. The enhancements extended the functional lifespan of the turbine structures and reduced future maintenance frequency.

LIDAR Equipment Decommissioning – Dalby, QLD

Client: DNV
Location: Dalby, QLD
Task: WindCube LIDAR Decommissioning

Our team removed and decommissioned remote sensing units used for wind data collection. The process included:

  • Equipment dismantling
  • Environmental compliance
  • Asset relocation coordination

The project was executed efficiently and safely, meeting regulatory standards and ensuring minimal impact on surrounding operations.

Blade Repairs and Technician Deployment – Wattle Point Wind Farm

Client: AGL
Location: Wattle Point, SA
Task: Blade Repairs, Service Support, Warehousing

Multiple ongoing contracts have included:

  • Blade inspections (2024–2025)
  • Blade repair campaign (2024–2025)
  • Wind turbine servicing
  • Long-term technician placement, supporting the daily wind farm operations
  • Warehousing and logistics support

This long-term engagement demonstrates Direct Wind Services’ role as a trusted operations partner for AGL, combining field, technical, and logistical expertise under one coordinated service model.

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