Hychem solution extends critical BlueScope Seawall for another 50 years

Hychem provided an advanced structural strengthening solution to remediate a critical steel sheet pile wall for BlueScope at their Port Kembla facility.

Utilising the innovative SPiRe® (Sheet Pile Repair) composite system, the project successfully enhanced the wall’s structural capacity and provided robust, long-term corrosion protection without any disruption to the port’s shipping operations.

The challenge

BlueScope Steel identified an urgent need to address corrosion and structural degradation on a vital sheet pile wall at their Port Kembla shipping terminal. The solution had to provide not only a fully structural repair but also long-term corrosion protection in the harsh marine environment. Crucially, the remediation work could not disrupt the continuous operation of the facility, demanding an efficient, non-invasive system that could be installed in an active port.

The engineered solution

Hychem’s SPiRe® system by QuakeWrap was selected as the ideal technology for this high-stakes application. SPiRe® consists of lightweight, prefabricated Fibre-Reinforced Polymer (FRP) panels that are installed to create a formwork around the existing wall, which is then filled with grout. This composite system both restores structural capacity and creates an impermeable, corrosion-proof barrier. The system was installed by the specialist marine contractor, Port & Hunter Commercial Diving, ensuring a safe and efficient application in the tidal zone.

The outcome

The project successfully delivered a robust structural repair that is engineered to provide a 50-year service life. The installation was completed on time and within budget, with no disruption to BlueScope’s shipping operations, demonstrating the efficiency of the SPiRe system. The result was a structurally sound and aesthetically pleasing seawall, fully protected from the aggressive marine environment for decades to come.