What was failing
BHI Coatings performs Splash Zone Piling Composite Repair for industrial plants in Alvin and across the Texas Gulf Coast.
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.
How BHI Coatings approaches Splash Zone Piling Composite Repair
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.
Assess and map
We gauge the piling through the splash zone to locate the worst metal loss and confirm the section that needs to be rebuilt and reinforced.
Surface preparation
We clean and roughen the wasted steel back to a sound, profiled surface so both the rebuild and the wrap bond properly.
Rebuild lost wall
We rebuild the thinned and wasted steel with a cold-applied 1000 Series composite to restore the original profile, with no welding.
Install the composite wrap
We build up engineered SuperWrap II layers over the rebuilt section to reinforce the pile and seal the steel from the splash zone.
Cure and return to service
We let the wrap cure, inspect the finished repair, and hand the piling back ready to carry its load.
The result
What Splash Zone Piling Composite Repair looks like
Repair and protection work of this kind, performed by BHI Coatings crews across the Texas Gulf Coast.
