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Babcock Australasia has successfully trialled an advanced composite repair technology that could significantly reduce maintenance times and improve fleet availability across the Royal Australian Navy and Royal New Zealand Navy.
The trials, conducted on three naval vessels, demonstrated how fibre-reinforced polymer composites can be used as a permanent alternative to steel for in-water repairs. The approach allows maintenance to be carried out more quickly and with greater flexibility over where and when work is undertaken, keeping ships operational for longer.
Unlike traditional steel repairs, the composite method requires no hot works and can cure rapidly, even underwater. It also reduces disruption to ship systems and crew while offering long-term durability and future opportunities to reduce overall vessel weight.
The technology was applied to a range of tasks, including deck section renewal on the Royal New Zealand Navy’s replenishment ship HMNZS Aotearoa, corrosion repairs to the hangar on HMNZS Te Mana, and a targeted floor remediation on the Royal Australian Navy’s HMAS Ballarat.
For the work, Babcock partnered with FUZE, a specialist in engineered composite solutions with experience in the mining and offshore oil and gas sectors, as part of its expanding regional supply chain.
On HMNZS Aotearoa, the repairs were completed in just eight days – compared with the four to six months typically required using conventional methods – and received Lloyd’s class approval within 24 hours.
Babcock Australasia managing director for marine, Simon Spratt, said the results of the trials were highly encouraging.
“These trials with the Royal Australian Navy and across ships in both Australia and New Zealand show there is another way to deliver repairs faster, with less disruption and at lower cost than traditional approaches,” Spratt said.
“By shortening maintenance periods and extending the life of critical assets, this technology improves fleet availability and supports Defence priorities around readiness and resilience. A coordinated regional approach also helps generate sustainment efficiencies that strengthen maritime capability across both nations.”
FUZE managing director Jason LeCoultre said the trials highlighted the practical benefits of modern composite engineering for naval forces.
“Working closely with Navy and Babcock over several years has allowed us to demonstrate how composite technology can reduce the impact of the repair process,” he said.
“By combining carbon or glass fibre with proven engineering, we can deliver permanent, load-bearing repairs that resist corrosion and conform to complex structures. The speed and flexibility of composites make them well suited to urgent repairs, supporting longer deployments, lowering costs and improving overall fleet readiness.”
Stephen Kuper
Steve has an extensive career across government, defence industry and advocacy, having previously worked for cabinet ministers at both Federal and State levels.
