Babcock Australasia has successfully trialed a new composite repair technology on ships from the Royal Australian Navy (RAN) and the Royal New Zealand Navy (RNZN), cutting maintenance times from months to days.

The Fiber Reinforced Polymer method offers a permanent alternative to steel, allowing repairs without hot works and curing even underwater. The technology was tested on HMNZS Aotearoa, HMNZS Te Mana, and HMAS Ballarat, addressing corrosion, deck renewals, and floor remediation. 

On the Aotearoa, repairs were completed in just eight days, compared with four to six months using conventional methods, and received Lloyd’s class approval within 24 hours.

Babcock partnered with FUZE, a composite solutions provider with experience in mining and offshore sectors, to deliver both scheduled and emergency maintenance. 

Modernizing Fleet Maintenance in Australia and New Zealand

The trials build on ongoing efforts by the RAN and RNZN to modernize fleet maintenance and repair capabilities. 

The RAN has steadily advanced its fleet sustainment capabilities through initiatives like Plan Galileo and the Regional Maintenance Centre Network. A $2-billion navy maintenance contract announced in November 2023 also sought to consolidate maintenance operations across major RAN vessels.

Meanwhile, the RNZN has invested in lightweight repair materials and rapid-response teams to enhance at-sea maintenance. 

The Frigate Sustainment Communications project, initiated in 2021, continues to modernize HMNZS Te Kaha and Te Mana, upgrading communications systems to maintain operational readiness and interoperability into the 2030s.