More than 1,500 deteriorated piles supporting the Nashville Wharf at the Port of New Orleans have been repaired using fiber reinforced polymer, helping to preserve one of the region’s most critical maritime infrastructure assets. This is one of the largest waterfront FRP strengthening projects undertaken in North America.
The $13.5 million rehabilitation project involved the repair and strengthening of approximately 1,500 circular concrete-filled steel piles supporting the wharf, which was originally constructed between 1961 and 1962. Working alongside PCL Construction, Royal Engineering and Design Engineering Inc., the project’s engineer of record, Fyfe supplied its proven LOCTITE Tyfo FRP structural strengthening solution to address severe corrosion and restore long-term structural performance without disrupting port operations.
“Projects of this scale demand solutions that perform reliably in harsh and highly challenging marine environments,” said Head of Civil Composites at Henkel, Mark Brand. “The Nashville Wharf rehabilitation showcases the ability of FRP structural strengthening systems to restore capacity, protect against future deterioration and significantly extend the life of essential infrastructure while minimizing operational disruption.”
After decades of exposure to tidal conditions, moisture and aggressive marine environments, Nashville Wharf’s steel piles had experienced extensive pitting and corrosion. In many locations, deterioration extended more than 13 feet vertically, with corrosion depths reaching up to a quarter inch. Significant steel loss had exposed the concrete-filled cores of the piles, raising concerns about structural integrity and long-term durability.
The challenge was compounded by the location of much of the deterioration below the mudline and underwater. Crews worked in tidal river conditions with fluctuating water levels, soft mud access points, elevated temperatures and high humidity. Temporary platforms, scaffolding, excavation works and specialist access systems were required to reach damaged sections while maintaining safe operations.
As a vital logistics asset for the Port of New Orleans, the wharf remained operational throughout the rehabilitation program, making construction efficiency and minimal disruption essential project requirements.
To meet these challenges, the project team selected Fyfe’s LOCTITE Tyfo FRP structural strengthening system, engineered specifically for demanding infrastructure environments. The system created a high-strength, corrosion-resistant structural jacket around each pile, restoring confidence in the long-term performance of the wharf’s substructure.
Despite these constraints, the project team consistently met their goals. Efficiencies improved throughout the project and helped deliver the rehabilitation ahead of schedule.
The completed rehabilitation has preserved a critical asset at the Port of New Orleans while avoiding the significant cost and operational impact associated with large-scale pile replacement.
Christopher Smith, Construction Manager at Royal Engineering, said:
“Utilizing the LOCTITE Tyfo SCH-41 fabric combined with the LOCTITE Tyfo SW-1S underwater epoxy system on the Nashville A Substructure Repairs Project proved to be a highly successful solution for both performance and long-term durability. The installation process was efficient, the material quality exceeded expectations, and the system integrated seamlessly with the project requirements.
“The overall outcome helped improve schedule efficiency, minimize future lifecycle costs, and deliver a high-quality finished product to the client. Based on the success of this project, we would confidently recommend the use of this FRP system for similar applications moving forward.”
By successfully rehabilitating approximately 1,500 deteriorated piles, the Nashville Wharf project demonstrates the growing role of advanced FRP strengthening systems in extending the life of aging infrastructure and helping asset owners maximize return on existing investments.
