Marine & Maritime

Splash Zone Piling Composite Repair

Wasted splash-zone piling rebuilt and reinforced with an engineered composite wrap, no welding and no pile replacement.

Leak Sealing Composite RepairCorrosion ProtectionMetal Repair
Structural piling rebuilt and wrapped with an engineered composite in the splash zone

The challenge

A structural piling wastes fastest in the splash zone, the band that wets and dries with the tide and stays loaded with oxygen and salt. Corrosion eats the steel there while the sections above and below the water still look sound, so the loss of wall thickness is easy to miss until it threatens the load the piling carries. Once the section thins enough, the structure loses capacity and the whole platform or jetty is put at risk. The owner needed the wasted section brought back and reinforced without welding on a load-bearing pile and without cutting it out.

Our approach

We start by gauging the piling above and below the waterline to find the worst metal loss in the splash zone. We clean and roughen the wasted section back to sound steel, then rebuild the lost wall with a cold-applied composite to bring the profile back. Over the rebuilt steel we install an engineered SuperWrap II composite, designed to carry load and reinforce the section without any hot work on the pile. The repair cures in place and the piling goes back to carrying its load with a barrier between the steel and the splash zone.

  1. Assess and mapWe gauge the piling through the splash zone to locate the worst metal loss and confirm the section that needs to be rebuilt and reinforced.
  2. Surface preparationWe clean and roughen the wasted steel back to a sound, profiled surface so both the rebuild and the wrap bond properly.
  3. Rebuild lost wallWe rebuild the thinned and wasted steel with a cold-applied 1000 Series composite to restore the original profile, with no welding.
  4. Install the composite wrapWe build up engineered SuperWrap II layers over the rebuilt section to reinforce the pile and seal the steel from the splash zone.
  5. Cure and return to serviceWe let the wrap cure, inspect the finished repair, and hand the piling back ready to carry its load.

The result

  • Wasted splash-zone section rebuilt in place without cutting out or replacing the pile
  • Piling reinforced with an engineered composite wrap and no welding on the load-bearing steel
  • Steel sealed from the wet-dry, salt-laden splash zone under one continuous barrier
  • Work delivered by factory-trained and factory-certified Belzona applicators

Belzona systems used

SuperWrap II1000 Series

In the field

Lost wall thickness rebuilt with a cold-applied composite before wrapping
Steel surface sealed and protected against corrosion in a marine environment
Local · Authorized · Supply + Apply

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