Our consultancy covers a broad range of investigations, advice and recommendations on problems and issues related to corrosion of plant and material. Some of the recent consulting projects are listed below.
Northrop Engineering
Survey of Sheet Piling
Expansion of facilities in the entrance of the Hunter River required the determination of the integrity of sheet piling. A thickness survey was undertaken of the extant piling and remaining service life estimated. A number of options were presented to enable the area to be remediated allowing for the erection of multi-story units on the site and the implementation of a 100 year service life of the development.
Newcastle Port Authority
Corrosion of Sheet Piling in Newcastle Harbour
An inspection of the original loading docks of Newcastle Harbour revealed areas of perforation at low water level. This was confirmed to be accelerated low water corrosion. Inspections of other docks in the harbour identified more serious areas of low water corrosion resulting in the decommissioning of most of these facilities.
Fremantle Port Authority
Identification of Cause of Corrosion
What appeared to be unusual orange growths on sheet piling were causing concern in the Port of Fremantle. Samples of the substance were collected for analysis. Anaerobic and aerobic culturing and consequent DNA sequencing of material recovered from the rust product identified some of the bacteria present. It was found that higher rates of MIC occurred closer to the live sheep loading wharves.
Australian Bureau of Meteorology
Corrosion Protection of Sea Height Recorders in the South East Pacific
Advice was sought regarding the corrosion protection required for the sea-height recording devices located throughout the south-east Pacific Ocean countries including Fiji, Cook Islands, Kiribati, Nauru and Solomon Islands. The remote recording devices are serviced on an irregular basis necessitating a minimal technology and low maintenance protection regime.
VSL Prestressing (Australia) Pty Ltd
Estimation of Service Life (Windsor Emergency Flood Bypass)
Section of this vital road link had to pass over a known flood plain. Analysis of the soil was used to determine the service life of the reinforcement mesh used in earthworks supporting the road. Calculations determined that service life of this critical road works would exceed the prescribed 100 years minimum.
Life prediction of buried steel pre-stressing members (Hail Creek Queensland)
Aggressive soils posed a problem for overpass reinforcement components. Analysis of recovered steel and soil gave a better idea of the problems faced and methods to contain the issue.
Analysis of soil date regarding its suitability as backfill (Karuah By-pass NSW)
During construction of this overpass some of the backfill was reportedly out of specification. Calculations were carried out to determine an estimation of the service life of the reinforcement so that project could continue.
NSW State Water
Copeton Dam Spillway Ropes (Northern NSW)
Inspection of spillway ropes identified the cause of premature corrosion to be related to bacterial activity.
Keepit Dam (Central NSW) and Copeton Dam (Northern NSW).
It was thought that stray current from the DC generators was causing corrosion of surrounding structures. Testing was carried out to confirm or otherwise the presence of stray DC current at the damsites.
Stramit Building Products
Roofing Fasteners
An investigation into the premature corrosion of roofing fasteners installed at Gympie Qld resolved the early failures.
Vinsi Partners
Coating Identification
OH&S concerns were expressed about the coatings on a conveyor tower that was being refurbished. Investigations and analysis showed that the building had been protected with lead-based paint and coal-tar epoxy coating requiring appropriate procedure during the repainting process.
Mt Townsend Solutions
Coating system on lintels
An investigation was carried out to determine the materials used and the thickness of the protective coating system used on lintels that had prematurely rusted on a building.  The block of units was built within 200m of breaking surf and the suitability of materials and the coating system was in question.
Aurecon Hatch
Identification of Corrosion Mechanism
Accelerated low water corrosion was observed on a significant port facility under construction causing alarm among the stakeholders. Bacterial testing of the corrosion product confirmed on-site observations that the cause of the premature corrosion was microbiological, exacerbated by water borne nutrients. After discussions a series of steps were recommended to mitigate the corrosion until the facility was finished and cathodic protection installed.
Worley Parsons
Acid Sulphate Soils in Proposed Marina
The client was conducting initial planning for a large coastal marina using steel mooring piles. The seafloor consisted of up to 5m of unreactive acid-sulphate soils which if left undisturbed created no problem. Once disturbed the soil releases hundreds of tonnes of acids in an irreversible reaction, wreaking havoc on the local environment. This project involved a research study into feasible methods to minimise the reaction of any released acid on the steel mooring piles and the environment.
Aliterm
Termite Barrier Failure
Aluminium termite barrier and damp-course perforated less than a year after installation in a tropical location. An investigation found that the brickwork was permanently wet, allowing the high pH of the mortar to corrode the aluminium.
