Project Details
Provincetown Marina, operated by Ocean Havens at the tip of Cape Cod in Massachusetts, is a premier destination serving seasonal and transient boaters with 100 slips accommodating vessels up to 250 feet and 100 moorings with launch service. The marina’s floating boat docks are supported by nine steel piles (eight at 36 inches and one at 30 inches in diameter), each rising approximately 24 feet from the concrete deck at low tide. Forbes Industrial Services, a division of R.J. Forbes Painting Contractor specializing in complex marine and industrial corrosion restoration, was engaged to restore these critical structural elements. The project was executed during the week of May 27-31, coordinating with negative low tides for optimal access, and included comprehensive surface preparation using Ultra High Pressure water blasting at 7,000–40,000 psi, followed by application of Carbomastic 615 epoxy mastic and Carboxane polyurethane finish coatings to protect against the harsh marine environment of Provincetown Harbor.
Project Challenge
The marina’s steel piles had begun showing significant signs of wear from constant exposure to the harsh marine environment, including relentless saltwater immersion, tidal fluctuations, and weather extremes. Surface rust, coating degradation, and potential pitting threatened the structural stability of the docks that support the entire floating dock system. Without intervention, Ocean Havens faced the prospect of costly downtime during peak season, safety risks for dock users, potential environmental concerns from debris entering the harbor, and ultimately the need for full pile replacement—a far more expensive and disruptive solution. The challenge was compounded by the need to work around floating docks encircling the piles, coordinate with tidal cycles for access, and ensure no contaminants entered the sensitive harbor waters while maintaining operations at this busy waterfront facility.
Project Solution
R.J. Forbes delivered a comprehensive restoration solution that prioritized safety, environmental protection, and minimal operational disruption. The team began with a thorough site visit and physical assessment to conduct a job safety analysis and develop a detailed work plan. By strategically scheduling the project around negative low tides, the crew gained optimal access to the critical low waterline areas. Environmental protection was paramount—Geotek fabric, net tarps, and staging were deployed to contain all paint chips and debris, ensuring zero materials entered Provincetown Harbor. The restoration utilized Ultra High Pressure water blasting at 7,000–40,000 psi to remove old coatings, rust, and contaminants from the low waterline upward, while upper sections were prepared to SSPC-SP 2/3 standards using power tools. In partnership with Carboline Coatings, a tailored coating system was applied: Carbomastic 615 epoxy mastic (selected for its excellent moisture tolerance and corrosion resistance in saltwater environments) from the low waterline to the pile tops, followed by a Carboxane polyurethane finish coat from the high waterline upward for superior gloss retention and long-term protection. The revitalized steel piles now provide extended structural integrity, ensuring uninterrupted service for boaters while avoiding the significantly higher costs and disruption of pile replacement.
