Marine & Port Steel Structures

In marine environments the cheapest structure is often the one with the least surface area to protect. We favor fewer, heavier members over many light ones, use closed hollow sections where they simplify coating and reduce water traps, and rationalize connection types to limit edges and crevices. Combining structural optimization with coating strategy reduces both initial cost and maintenance, which drives the true cost of port assets over their design life.

Typical members include heavy rolled sections, built-up girders, hollow section trusses for conveyor galleries and equipment support frames. We grind sharp edges to a radius suitable for coating adhesion, seal weld where specified to prevent crevice corrosion, and drain or vent hollow sections for galvanizing.

Welding follows the AWS D1.1, AS/NZS 1554.1 or EN 1090 requirements specified for the project, with care taken over weld profiles that coat cleanly and spatter removed before blasting. Piece marks are applied so they remain legible after galvanizing and painting, and lifting lugs are positioned to limit coating damage, helping crews identify and handle each piece correctly in exposed quayside conditions.

Our inspection and test plan for marine structures places extra emphasis on surface preparation and coating. Materials are traced to mill certificates, and welds are inspected visually with magnetic particle or ultrasonic testing where specified. We verify edge rounding, surface cleanliness, profile and ambient conditions before coating, then record dry film thickness and adhesion results. Dimensional checks confirm fit of girders and gallery segments, and all records are compiled in a QC dossier.

Coastal and port sites typically fall within ISO 12944 C5 or CX, with splash and tidal zones demanding the highest protection. We commonly specify hot-dip galvanizing to EN ISO 1461 or AS/NZS 4680 followed by a compatible paint system, forming a duplex system for long durability. Coating choices consider design life, the practicality of maintenance access and the risk of damage from cargo operations, and touch-up procedures are defined for site use.

Coated steel for ports must arrive undamaged, because repairs in a marine environment are difficult to perform well. We pack members with protective dunnage, edge guards and wrapping, and sequence shipments by erection zone so pieces are not stored on site for long. Larger girders and gallery segments ship as break-bulk with engineered stowage, smaller items in containers. Export documentation, packing lists and coating repair kits accompany the delivery.

We support erection with drawings, lifting data and a recommended sequence that minimizes handling of coated pieces. Our engineers provide method statement input on lifting points, temporary bracing for wind exposure and protection of coatings during lifting. We define site touch-up procedures and inspection points. Where agreed, we provide technical supervision or advisory visits during critical lifts and final coating inspection.