Leading Edge Protection and Repair Solution. Power Plant, Chile.

Restoring Power and Performance: How Resimac SA’s Leading Edge Protection Revived Turbine Efficiency.

In power generation, every turbine blade plays a critical role in maintaining performance, efficiency, and operational stability. However, over time, constant exposure to high-velocity particulate matter can cause severe erosion, especially along the leading edges of turbine blades. This type of wear not only compromises the blades’ aerodynamic efficiency but can also lead to vibration issues, increased maintenance costs of bearings as well as reduced power output.

When a leading power generation facility faced significant turbine blade erosion, they turned to Resimac SA for a solution that could restore the blades’ integrity and provide long-term protection against further damage.

Understanding the Abrasion Challenge.

A Power plant in Chile, abrasive particles in the airflow have steadily eroded the leading edges of the turbine blades. This abrasive particle wear causes surface pitting, reduced aerodynamic smoothness, and negatively impacts the turbine’s overall efficiency.

Replacing the blades entirely would have been time-consuming, costly, and would result in extended downtime, something the client could not afford. The challenge was clear: restore the damaged turbine blades quickly, effectively, and sustainably while ensuring durability under continued abrasive conditions.

The Resimac SA Solution: Advanced Leading Edge Protection Surface Restoration and Protection.

Resimac SA provided a comprehensive repair and protection solution that addressed both restoration and long-term resilience. The process combined advanced surface preparation, precision restoration with high-performance metal repair compounds, and application of a specialised protective coating designed to resist erosion.

Step 1: Surface Preparation.

The turbine blades were abrasive blast cleaned to ISO 8501/4 SA2.5 standard, achieving a 75-micron angular profile. This ensured the surface was free of contaminants and perfectly textured for maximum adhesion.

Step 2: Structural Restoration.

All pitted and worn sections were rebuilt and reshaped using Resimac 101 Metal Repair Paste, a metal-reinforced polymer composite engineered for high-strength repairs. This step restored the original aerodynamic contours of the blades, reinstating their structural integrity and balance.

Step 3: Protective Coating Application.

To complete the process, the blades were coated with Resimac 203 Super Flow, applied in two layers to achieve a total dry film thickness of 500 microns. This high-performance coating formed a smooth, wear-resistant barrier designed to withstand continuous high-speed particulate impact and resist corrosion.

(Learn more about these products: 101 Metal Repair Paste | 203 Super Flow)

The Results: Efficiency Restored, Downtime Reduced.

The transformation was immediate and measurable. The repaired turbine blades not only regained their original structural strength but also demonstrated superior resistance to operational stress and abrasion. The smooth finish achieved with 203 Super Flow enhanced aerodynamic flow, reducing energy losses and improving overall turbine efficiency.

The benefits included:

• Extended blade lifespan, thanks to superior erosion and corrosion protection.
• Improved operational efficiency, with smoother airflow and reduced drag.
• Reduced vibration and wear, leading to greater mechanical stability.
• Minimized downtime and costs, avoiding the expense of full blade replacement.
• Enhanced sustainability, as the repair method extended asset life and reduced material waste.

Savings That Go Beyond the Repair.

The cost of complete turbine blade replacement can be astronomical, both in terms of materials and lost productivity during downtime. By opting for Resimac’s advanced repair system, the client realized significant financial savings while also maintaining continuous operation.

This solution proved that smart repair and protection are far more sustainable and cost-efficient than replacement. Moreover, the ease of on-site application minimized disruption, allowing maintenance teams to restore full function rapidly.

Resimac SA Leading Edge Protection Proven Performance and Reliability.

Resimac SA has built a strong reputation across industries for delivering engineering-grade composite repair and protection systems that perform under extreme conditions. This turbine repair project stands as a testament to Resimac’s expertise in combining science-backed materials with real-world industrial experience.

Clients across the energy, marine, and manufacturing sectors rely on Resimac SA’s solutions to extend equipment lifespan, improve performance, and reduce total cost of ownership.

Why Choose Resimac SA?

• Technical Expertise: Decades of experience in polymer engineering and industrial coatings.
• Global Standards Compliance: Repairs meet international quality and performance standards such as ISO 8501/4 and SSPC SP10/NACE 2.
• Proven Products: Resimac 101 and 203 are trusted worldwide for their exceptional durability and performance in demanding environments.
• Sustainability Commitment: Helping industries extend the life of their assets while reducing waste and emissions.

Powering a More Efficient Future with Resimac SA.

For industries where performance, efficiency, and longevity are non-negotiable, Resimac SA’s Leading Edge Protection Solution represents the future of smart maintenance. Instead of costly replacements, businesses can now restore, protect, and enhance their assets using cutting-edge polymer technology.

By combining innovation with practicality, Resimac continues to help power generation companies and other industrial operators stay efficient, sustainable, and competitive—one repair at a time.

Ready to improve the performance and lifespan of your equipment?
Visit www.resimacsa.co.za to learn more about our advanced repair and protection solutions.

Partner with Resimac SA.

With extensive experience and a focus on innovation, Resimac SA is your trusted partner in the power generation industry. Our advanced coatings are designed to protect your assets, enhance efficiency, and reduce operational costs.