Port Kembla Harbour encountered a failure of hot rolled steel Z sheet piles. Specifically, a small number of these Z sheet piles became disconnected from the clutch shortly after installation.

BG&E Materials was engaged to develop a methodology to test the steel and investigate the cause of this failure.

The works undertaken by our team included

• The development of sampling and testing methodologies to confirm the properties of the steel and investigate the failure that had been reported.
• Hardness testing and micrographic examinations of steel to identify any differences in microstructure that may be indicative of changes in steel properties, confirmation of mechanical properties and chemical composition to confirm steel grade and properties, and assessment of welds.
• A macrographic examination of the sheet pile and clutch to confirm the profiles, as a part of the methodology.

The results of the testing were analysed by BG&E along with available information and drawings to confirm conformance of the steel to relevant ISO standards for hot rolled Z sheet piling, quality of the steel, and welding. The review also identified possible causes that may have contributed to the failure of the sheet piling that require further investigation.