Corrosion Inspection for Iconic Sydney Harbour Bridge

Client: Transport for NSW
Project: King Posts
Location: Sydney, NSW

The Sydney Harbour Bridge (SHB) is one of Australia's most iconic landmarks and is recognized worldwide as a symbol of modern engineering. The Bridge was constructed in the first half of the 20th century, and while it has undergone numerous renovations and repairs, it is still subject to the challenges of time and the harsh Australian environment. In recent years, corrosion of the King Posts, the vertical steel columns at the end of the arch that link the base, has become a significant issue. ICS, a leading provider of corrosion solutions, was tasked with developing a solution to protect the King Posts from further corrosion while ensuring the safety of workers and the public. In this customer story, we will explore the challenges faced by ICS and the innovative solution they developed to address this critical issue.

Challenge

The Sydney Harbour Bridge is an iconic landmark that has been standing for almost a century. However, due to its age and construction, it has many areas where the trusses do not allow for the application of coatings to protect them, leading to areas of corrosion. One such area is the King Posts, steel vertical columns that link the base and carry the entire load of the bridge. These columns were painted in the 1980s with lead paint, and by 2021, heavy corrosion was evident in each post's three separate voids extending from the road deck to the water level.

Solution

ICS worked with engineers and access companies to design and install an innovative system of inspection and treatment that allowed these tricky areas to be accessed, blasted, painted, and inspected with minimal risk to workers and the public. The ICS team modified a rotating head pipe blasting unit to perform a pre-blast of the area, removing most of the lead-based paint before a technician entered the areas to catch any misses. The coatings were then applied in the confined space using a powered roller.

Implementation

Over 18 months, ICS completed inspections and provided supervision for the project. The ICS team delivered an outstanding quality result for the project, with a focus on safety, quality, and efficiency throughout the process.

Results

The ICS solution resulted in a significant improvement in the structural integrity of the Sydney Harbour Bridge. The inspection and treatment system delivered a lasting result that protects the bridge from future corrosion. The innovative system also provided increased efficiency, cost savings, and reduced downtime, minimizing disruption to traffic and the public.

The ICS team's commitment to safety and quality was evident throughout the project, with a focus on minimizing risk to workers and the public while delivering a high-quality result. The use of the rotating head pipe blasting unit and powered roller allowed for efficient and effective treatment of the King Posts, and the attention to detail during the inspection and treatment ensured a lasting solution to the corrosion issues.

The Sydney Harbour Bridge is an iconic structure that is important to the people of Sydney and Australia, and the ICS team is proud to have contributed to its ongoing maintenance and preservation.