CORROSION PREVENTION

Corrosion PreventionSpecialists in the

Marine Sector

Spanning more than 45 years, Denso Australia has been manufacturing and supplying a range of SeaShield products in the prevention of corrosion for

subsea and marine environments.

Denso SeaShield systems are well known globally for cost effective long-term protection for timber, concrete and steel marine structures.

We are able to demonstrate our knowledge and experience through some iconic projects across Australia and New Zealand markets.

Our dedicated team is committed in offering effective solutions in combating corrosion and delivering high quality products and exceptional service to our clients.

CORROSION PREVENTION

CORROSION PREVENTION

Electronet Transmission Towers

Port Augusta SA

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Electronet Transmission Towers

Port Augusta SAThe Port Augusta Power station is situated at the very top of the Spencer Gulf in South Australia. The power station supplies electricity to western and central rural sectors of South Australia.

Six large transmission towers span across the gulf on its way to the Eyre Peninsula. Each transmission tower has 4-6 feet that are supported by numerous pylons and concrete soffits.

Denso Australia was approached by Elec-tronet to offer a long term solution for protec-tion of the steel pylons from corrosion.

Seashield 2000FD was agreed as the best product solution for the project. The pile struc-ture was quite complex comprising of two sof-fits and two sections of wrap on each pylon.

The main contract was awarded to Marine and Civil Maintenance Pty Ltd, who was the principle contractor and project managed the entire concrete soffit rehabilitation.

Whyalla Diving Services Pty Ltd, a local “Denso approved” diving company, installed the Seashield system. The project was com-pleted ahead of schedule and the client was extremely pleased with the completed works and end result.

SeaShield 2000FD was agreed as the best product solution for the project.

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CORROSION PREVENTION

Appleton Dock Port Melbourne Vic

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The Appleton Dock Pile Rehabilitation Project at the Port of Melbourne was successfully tendered for by Denso (Australia) Pty Ltd and Professional Diving Services based on reputation, project proposal and product selection.

Appleton Dock Pile Rehabilitation Project Port Melbourne Vic

The Denso SeaShield 400 and 70 Systems were the products of choice and specified by GHD for the rehabilitation of 1,200 timber piles ranging from 600mm diameter to 400mm in diameter. Protected pile lengths varied from 1.5 meters to 8 meters.

The SeaShield range of materials used on this project comprised of 2,500 lineal meters of Denso fibre form jackets, 3,000sqm of Denso C-Grid® 450, 27,000 bags of Denso 510 underwater grout (30 x 20ft shipping contain-ers), 5,500 rolls of Denso Marine Piling Tape and 7,000 lineal meters of Denso Glass Outer-wrap FX.

The Denso SeaShield 400 and 70 Systems were the

products of choice.

This project took 12 months to complete and the success of the project is being showcased as an example globally, for the refurbishment of timber structures.

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CORROSION PREVENTION

Doyles Restaurant Watsons Bay NSW

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Doyles Restaurant Watsons Bay NSW

Denso Australia in conjunction with Preserva-tion Technologies, undertook the remediation works of (23) H piles under Doyles Restaurant, Watson Bay, NSW.

SeaShield 100 Series was the recommended and the preferred corrosion protection system for the remediation.

The original concrete pile protection had never fully protected the H piles, which had caused the piles to become severely corroded. Much of the concrete had also fallen away, exposing bare steel H piles for some time. The original concrete protection was removed by jack hammering and the piles were me-chanically cleaned by way of a needle gun.

Once completed and inspected to ensure a thoroughly clean surface had been achieved, SeaShield Primer (P) was applied to the H pile followed by SeaShield Seal (T) Tape, from top to bottom.

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The tape followed the contour of the H pile whilst achieving a constant 55 per cent over-lap. Foam blocks were tightly squeezed into the voids and positioned on both sides of the pile, creating a cylindrical shape. Any remain-ing small voids were filled with SeaShield Mastic. SeaShield Seal (T) tape was then reapplied around the entire foam infills to fully encapsulate the entire pile.

SeaShield Series 100 HDPE jackets were then installed and fastened using 19mm SmartBand and low profile buckles. The straps were positioned 50mm from both the top and bottom and at 200mm intervals, to fully secure the jacket into place.

SeaShield 100 Series was the recommended and the

preferred corrosion protection system for the

remediation.

CORROSION PREVENTION

Lucinda Sugar Terminal

Queensland Sugar Limited

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Lucinda Sugar Terminal Queensland Sugar Limited

Early 2013 Queensland Sugar Limited (QSL) appointed locally based Advanced Aqua Blasting (AAB) as principal contractor for the repair and installation of corrosion systems to the 6.2 km jetty.

This appointment was the initial stage of a 10 year progressive installation of the 800 jetty and wharf piles, as well as repairs and corrosion coverage on some of the worst affected headstocks using the Steelcoat 400 (Ultraseal bitumen tape) system.

AAB are now in their third year of installing 2000FD jackets after previous work wrap-ping the conveyor tunnel with Denso Pet-rolatum tapes as cyclone and maintenance repairs.

Works are being completed from a three level drop scaffold arrangement to access the pile from +1.5m L.A.T to headstock level +6.7m L.A.T with the expectation that some areas may be accessed using a pile mainte-nance vehicle to complete works without the cost of scaffolding.

Subsequently QSL has commenced works at their Bundaberg Sugar Terminal with the Denso Seashield 2000FD, with the expecta-tion of a 30+ design life at both facilities.

The various Denso systems used around their QLD terminal facilities delivered and met the client’s requirements. AAB and QSL are keen to show case to other facility operators their knowledge in cost effectively applying Denso systems for a long term duration with low/no maintenance required for 30+ years.

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CORROSION PREVENTION

Shoal Bay WharfGreat Barrier Island NZ

Four and a half hours by car ferry, directly east from Auckland lays the Great Barrier Island. It is a remote location with only around 800 inhabitants. The ferry service is critical to the lifeblood of the island bringing tourists and essential supplies.

Sitting southwest of the island in the Tryphena Port is the vital Shoal Bay wharf. The current structure is around 40 years old and constructed of treated pine piles and hardwood braces. These are now in need of renewal. However, the piles support a working structure, which strategically for the island and its people, cannot be decommissioned. STF Limited, marine asset maintenance special-ists, called upon Denso to help renew the wharf piles without any disruption to the working wharf.

Denso SeaShield 400 Series was specified to not only protect the timber piles against further ma-rine borer attack, but also to ensure that an eco-nomical long lasting solution is provided.

Denso New Zealand was on hand to provide as-sistance for this system installation, a first in New Zealand. As timber piles can be irregular in pro-file, an on-site challenge was how to establish a base seal to suit what turned out to be an uneven pile profile. The solution was to wrap SeaShield Piling Tape around a 50mm base foam seal and insert this from under the installed jacket. Holes were dug around the piles so that the jackets were embedded in the mud-line.

The wharf had many braces, which posed a challenge when trying to incorporate the brace pin into the GRP jacket. The solution was to pour two grout plugs – the first to provide the main grout plug at 300mm. With the brace pin hole drilled through the jacket at 450mm and sealed on the inside with SeaShield Tape and on the outside with Glass Outerwrap, the sec-ond plug was poured just above this height.

With the operation being undertaken between shipping schedules, this solution to extending the life of this essential asset has proved to not only be a practical one, but also an economical one. For years to come, visitors to the stun-ningly beautiful Great Barrier Island can con-tinue to arrive at a safe and structurally sound wharf.

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BP Refinery Jetty StructureSouth of Fremantle WA

The BP Refinery Jetty Structure located South of Fremantle in Perth Western Aus-tralia was constructed in 1953. Originally the project was known as the Anglo-Iranian Oil Co. LTD Kwinana Refinery Project.The jetty structure consists of some 900+ hexagonal piles x 464.5 OD.

Denso (Australia) Pty Ltd was invited to submit a proposal for long term pile protec-tion and restoration.

Denso’s enviable reputation as the lead-ers in long term corrosion prevention in extreme environments meant we were able to tailor design a system to suit the heavily corroded hexagonal shaped piles.

The SeaShield 2000FD system was cho-sen due to its track record and Denso’s standing as a long term partner in corrosion prevention.

Denso’s enviable reputation as the leaders in long term

corrosion prevention in extreme environments meant we were able to tailor design a system to suit the heavily corroded hexagonal shaped

piles.

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CORROSION PREVENTION

Denso SeaShield Systems Protection Options

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Seashield Systems Pile Tape Syste m Design Life

Suggested System Maintenance Description for UseConcrete Steel Timber

Tape

Denso - SeaShield Series 60 System ● 10+ yearsBi-annual inspection.

For use on timber pile jetties to provide splash or tidal zone protection for piles subject to organism attack in sheltered en-vironments. Primer and tape components can be applied to the mud line to help deprive the Toredo worm of oxygen and act as a barrier to prevent further worm ingress. Full system components are: SeaShield Primer P, SeaShield Marine Piling Tape, Ultraflex 1500 Tape, Rockmesh, SmartBand Strapping and buckles.

Denso - SeaShield Series 70 System ● 15+ years Bi-annual inspection.

For use on timber piles to provide splash or tidal zone protec-tion for piles subject to organism attack in relatively sheltered environments. Full system components are: SeaShield Primer P, SeaShield Mastic (profiling and filling irregular surfaces), Marine Piling Tape, Densoglass FX Outerwrap, compression film (cling film) for use during product cure only.

Denso - SeaShield Series 80 System ● ● 10+ years Bi-annual inspection.For use on steel pile jetties to provide splash or tidal zone pro-tection for piles subject to corrosion in sheltered environments. Same full components as listed in SeaShield Series 60.

Jacket

Denso - SeaShield Series 100 System ● ● 15+ years Bi-annual inspection.

For use on steel and concrete loading wharfs, jetties, dolphins, piers and beacons. Ideally suited for pile Ø 700mm or less in harbour / sheltered environments. Full system components are: SeaShield Primer P, Seal (T) Tape or SeaShield Marine Piling Tape, Series 100 HDPE Jacket, SmartBand Strapping and buck-les - 19mm.

Denso - SeaShield Series 250 System ● 7+ years

Bi-annual inspection of jackets required. Damage from barges or work boats can occur.

The system is designed to encapsulate and deprive the Toredo worm of oxygen, thus suffocating it in the splash or tidal zone. It also protects timber piles in marine environments from deteriora-tion due to low to moderate tidal flows, marine growth, and sea conditions. Used only on timber loading wharfs, jetties, dolphins, piers and beacons. Requires piles to structurally meet with capacity requirements prior to application. System components include heavy duty fabric jacket with fibreglass rods, SmartBand Strapping and buckles - 19mm.

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CORROSION PREVENTION

Denso Seashield Systems Protection Options Cont.

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Seashield Systems Pile Tape Syste m Design Life

Suggested System Maintenance Description for UseConcrete Steel Tim-

berJacket

Denso - SeaShield Series 250HD System ● ● 15+ yearsFive year maintenance schedule of jackets re-quired. Damage from barg-es or work boats can occur.

The system protects piles in marine environments from dete-rioration due to moderate tidal flows, marine growth, and sea conditions. Used on steel loading wharfs, jetties, dolphins, piers and beacons. Requires piles to structurally meet with capac-ity requirements prior to application. Full system components are: SeaShield Primer P, SeaShield Seal (T) Tape or SeaShield Marine Piling Tape and heavy duty fabric jacket with fibreglass rods.

Denso - SeaShield Series 2000FD ● ● 20+ years

7-10 years visual inspec-tions of jackets. Mechanical-ly damaged to be replaced. Damage from barges or work boats can occur.

Splash zone protection of pilings in harsh marine environments. Components of this system are Seashield Primer P, Seashield Marine Piling Tape, and Denso Series 2000FD Jacket. Ideally suited for pile Ø 400mm or greater. Requires piles to structur-ally meet with capacity requirements prior to application.

Epoxy Encasement (Non-Structural)

Denso-SeaShield Series 500 ● ● ● 25+ yearsZero

The Series 500 System is tough, durable and provides the ultimate protection to restore steel, concrete and timber piles. Components of this system are the Denso Series 500 Fibre-glass Jacket (GRP) and Denso 550 Epoxy.

Concrete Encasement (Structural)

Denso - SeaShield Series 400 ● 20+ years Zero

Structural repair system that doubles the strength of the original timber pile. Blowouts can be avoided with pouring of bottom plugs. Spacers should be used to prevent movement of the C-Grid 450©. Components of this system are the Denso Series 400 Fibreglass Jacket (GRP), C-Grid 450© and Denso 510 UW cementitious grout.

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Denso SeaShield systems provide cost effective long-term protection in highly

corrosive environments and in sub-sea conditions.

ContactMelbourne

Denso (Australia) Pty Ltd411-413 Victoria StreetBrunswick Vic 3056

T: 1300 658 590

www. densoaustralia.com.au

CORROSION PREVENTION