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Oclyte Tuff Coat™ required for tough Wellington conditions
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Principal: New Zealand Transport Agency (NZTA)
Consultant: Opus International Consultants Wellington
Contractor: Fulton Hogan Wellington
Location: SH1 Ngauranga Flyover
Product: Oclyte Streetlight Columns and Oclyte Tuff Coat™
After an inspection of the balance of the columns on the flyover it was decided that 15 columns needed replacing due to corrosion.

When Willie Mandeno from Opus International Consultants, was completing his periodic structural inspection of the Ngauranga Flyover on behalf of NZTA, he noticed a horizontal rust stain on one of the lighting columns.

"I happened to notice a rust stain at the base weld of one of the columns," said Willie. "It looked very much like a fatigue crack which is something that could occur with the extreme wind loading that this location produces. I took photographs and forwarded them to CSP Pacific who recommended that the column be removed for closer inspection of the weld. This is where Clem at Fulton Hogan became involved."

"It wasn't until we removed the column to inspect it properly that we saw how badly corroded the inside of the column was," said Clem Geraghty, Electrical Supervisor, Fulton Hogan's Wellington region. "I was surprised to see that the column was rusting from the inside out. The exterior galvanised coating was almost disguising the problem from the outside. We think that the columns may have rusted from the inside out due to a condensation build up."

After an inspection of the balance of the columns on the flyover it was decided that 15 columns needed replacing due to corrosion.

"We have replaced the 7 columns that fit to the corbels on the flyover with 8 still to be installed to the approaches," added Clem. "We are pretty sure they are the original columns that were installed when the flyover was first built in 1984 so they have had a very good life considering the salt spray and the wind that Wellington harbour produces."

The new columns have:

  • A drainage system - which should prevent condensation build up in future
  • A curved outreach design - which is better suited to high wind locations
  • A base which has been coated internally and externally with CSP Pacific's Oclyte Tuff Coat™. With a 20 year system warranty Oclyte Tuff Coat™ will assist in extending the service life of these columns past that of the original columns.

"The staff at CSP Pacific have been really helpful on this upgrade," says Clem. "Jeremy, Sue and Lawrence have all assisted in analysing the issues and coming up with a solution."


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