More than 1,500 deteriorated piles supporting Nashville Wharf at the Port of New Orleans have been repaired and strengthened in one of the largest waterfront fibre-reinforced polymer (FRP) rehabilitation projects of its kind in North America.
The project used Fyfe’s LOCTITE Tyfo FRP structural strengthening system to restore steel piles affected by decades of exposure to tidal fluctuations, moisture and aggressive marine conditions.
The Nashville Wharf piles were originally constructed in 1961 and 1962. Over time, many had developed extensive corrosion and pitting, with deterioration in some locations extending more than 13 feet vertically. Corrosion depths reached up to one-quarter inch in places, and significant steel loss had exposed the concrete-filled cores of some piles.
Marine Conditions Created Complex Repair Challenges
The rehabilitation work was complicated by the location of much of the damage below the mudline and underwater. Crews worked in tidal river conditions, with fluctuating water levels, soft mud, limited access, high temperatures and high humidity all affecting the repair programme.
Temporary work platforms, scaffolding, excavation and specialist access methods were required to reach affected areas safely. The project team included PCL Construction, Royal Engineering and Design Engineering Inc., the engineer of record.
The selected FRP system creates a high-strength, corrosion-resistant structural jacket around each pile. The aim was to restore structural integrity and provide longer-term protection against future deterioration, while avoiding the disruption and cost associated with large-scale pile replacement.
“Projects of this scale require solutions that can perform reliably in some of the most demanding marine environments,” said Mark Brand, Head of Civil Composites at Henkel. “The Nashville Wharf rehabilitation demonstrates how FRP strengthening systems can restore structural capacity, protect against future deterioration, and significantly extend the service life of essential infrastructure, all while minimising disruption to ongoing operations.”
Port Operations Continued During Works
The $13.5 million programme addressed severe deterioration while allowing the port to remain operational throughout construction. Despite the difficult site conditions, the project team improved installation efficiency during the works and completed the rehabilitation ahead of schedule.
The project has preserved a strategically important wharf asset for the Port of New Orleans and reduced the need for more disruptive replacement works.
“The use of LOCTITE Tyfo SCH-41 fabric in combination with the LOCTITE Tyfo SW-1S underwater epoxy system proved to be an outstanding solution for the Nashville A Substructure Repairs Project,” said Christopher Smith, Construction Manager at Royal Engineering. “Installation was efficient, material performance exceeded expectations, and the system integrated seamlessly into the project’s requirements.”
“The successful outcome improved schedule efficiency, reduced anticipated lifecycle costs, and delivered a high-quality result to the client. Based on our experience, we would confidently recommend this FRP system for similar rehabilitation projects.”
The project reflects a wider challenge for ports, utilities and infrastructure owners managing ageing assets in harsh marine and waterfront environments. Structural rehabilitation technologies are increasingly being used to extend asset life, reduce downtime and limit the environmental and operational impacts of full replacement.
FAQs
What work was completed at Nashville Wharf?
More than 1,500 deteriorated steel piles supporting Nashville Wharf at the Port of New Orleans were repaired and strengthened using FRP structural strengthening technology.
Why did the wharf piles need rehabilitation?
The piles had suffered corrosion and pitting after decades of exposure to tidal fluctuations, moisture and aggressive marine conditions.
What is FRP strengthening?
FRP, or fibre-reinforced polymer, strengthening uses composite materials to add structural capacity and corrosion resistance to existing infrastructure assets.
Was the Port of New Orleans able to keep operating?
Yes. The rehabilitation programme was delivered while the port remained operational.
Who was involved in the project?
The project team included Fyfe, Henkel, PCL Construction, Royal Engineering and Design Engineering Inc.
