CH4 Global – Structural Audit

The facility comprises a single-storey portal framed industrial building, incorporating:

• Steel columns, rafters, trusses, and purlins
• Bondor insulated wall and ceiling panels
• Large biofilter and tank systems used for aquaculture processes
• Internal access systems including walkways, ladders, and pipe racks

As shown in the aerial layout and internal arrangement, the building is divided into:

• Biofilter Area – housing treatment systems and access walkways
• Tank Area – containing large operational tanks for processing

The structure operates in a highly aggressive coastal environment, located within approximately 500 metres of seawater exposure, with continuous internal humidity due to open water processing systems.

• Continuous exposure to salt-laden air and high humidity accelerated corrosion across structural and non-structural elements.
• The facility had been inactive for approximately 12 years, resulting in deferred maintenance and undetected deterioration.
• Transition from fish farming to seaweed processing introduced:
• Increased internal moisture
• Additional service loads (cabling, equipment)
• Structural Degradation of Critical Elements
• Steel columns exhibited significant section loss at base regions (up to complete perforation in areas)
• Corrosion near bracing connections increased structural vulnerability under lateral loads
• Walkways and ladders were found to be non-compliant with Australian Standards (AS1657).
• Roof and wall leakage resulted in trapped moisture within wall panel channels, accelerating internal corrosion.

Incon delivered a detailed engineering audit supported by practical remediation strategies:

Structural Integrity Assessment

• Visual inspection of all primary and secondary structural elements
• Identification of corrosion severity and structural risk zones
• Assessment of load paths and potential failure points

Targeted Remediation Strategy

Steel Columns

• Installation of reinforcing steel plates (10mm thick) at corroded zones
• Localised strengthening where section loss exceeded acceptable limits
• Surface preparation and application of high-build epoxy protective coatings

Wall Systems (Bondor Panels)

• Replacement of severely corroded base channel flashings
• Sealing of joints to prevent water ingress
• Protective coating for minor corrosion areas

Pipe Racks, Walkways and Access Systems

• Replacement of corroded pipe support elements
• Recommendation to decommission and redesign walkways to comply with AS1657
• Strengthening or replacement of corroded connections and supports

Corrosion Protection Strategy

• Adoption of surface-tolerant epoxy coating systems for long-term durability
• Emphasis on maintenance planning for coastal environments

The structural audit enabled CH4 Global to:

• Clearly understand the extent and severity of structural deterioration
• Identify critical structural risks requiring immediate attention
• Implement targeted remediation to extend the service life of the facility
• Improve safety compliance, particularly for access systems
• Establish a foundation for ongoing maintenance and asset management

The project ensured that the facility could continue operating safely while supporting CH4 Global’s innovative aquaculture processes.

• Early identification of structural risks in a corrosive marine environment
• Practical and cost-effective strengthening solutions avoiding full replacement
• Integration of compliance upgrades (AS1657) into remediation strategy
• Enhanced asset longevity through targeted corrosion protection systems
• Clear, actionable reporting supporting client decision-making