Project Details
Waterside Marina, located in the protected waters of Cos Cob Harbor in Greenwich, Connecticut, serves as a premier destination for boating enthusiasts along the Long Island Sound. The marina offers slips for vessels up to 50 feet, providing convenient access just south of the I-95 bridge. R.J. Forbes Painting was contracted to restore the marina’s 522-foot steel sheet pile seawall, which had deteriorated significantly after over two decades of continuous exposure to tidal surges and saltwater immersion. The project required meticulous surface preparation using 40,000 psi Ultra-High Pressure water blasting to achieve SSPC-SP 10 near-white metal standards, followed by the application of a specialized three-layer water-based moisture-cured coating system totaling 13.0–19.0 mils DFT. Our certified marine coating specialists coordinated all work with tidal schedules, utilizing floating docks, barges, and work boat platforms while implementing comprehensive environmental protection measures, including silt curtains, to ensure zero harbor contamination.
Project Challenge
Waterside Marina’s critical steel sheet pile seawall—essential for soil retention and waterfront protection—had faced severe deterioration due to over 20 years of relentless environmental exposure to saltwater, tidal action, and marine conditions. The structure exhibited widespread rust flaking, deep pitting throughout the sheet piles, and compromised protective coatings, leaving the steel vulnerable to accelerated corrosion. The marina required a cost-effective restoration solution that would extend the seawall’s service life without the expense and disruption of complete replacement. Additionally, the project demanded careful coordination with tidal cycles, strict adherence to marine environmental regulations, and specialized access methods to reach all affected surfaces while maintaining normal marina operations and protecting the sensitive harbor ecosystem.
Project Solution
R.J. Forbes Painting deployed our certified marine coating specialists to execute a comprehensive in-situ restoration strategy, eliminating the need for costly demolition. Our team conducted a thorough assessment to identify corrosion hotspots, then established safe working platforms using floating docks, barges, and work boats synchronized with low-tide windows for optimal access. Crew members, equipped with full PPE and harness systems, performed surface preparation using 40,000 psi Ultra High Pressure (UHP) water blasting—an eco-conscious, non-abrasive technique that methodically stripped away legacy coatings, rust, contaminants, and chloride deposits to achieve a pristine SSPC-SP 10 near-white metal profile. We then applied a high-performance, moisture-cured Wasser coating system engineered explicitly for severe marine exposure: MC-Miozinc 100 primer (3.0–5.0 mils DFT) for galvanic and barrier protection, followed by two layers of MC-ECO TR 100 intermediate and topcoat (5.0–7.0 mils DFT each) using a coal tar-free urethane formulation for superior corrosion resistance and UV durability. The complete system achieved an average DFT of 16 mils for optimal longevity. Throughout the project, we deployed temporary silt curtains. We adhered to strict low-tide scheduling protocols to ensure zero environmental incidents, delivering a seamless and disruption-free restoration that protects Waterside Marina’s waterfront infrastructure for years to come.
