Abstract This article briefly describes a project carried out by the Defence Science and Technology Organisation (DSTO) for the Royal Australian Navy in which the principal objective was to investigate the suitability of bonded composite technology to reinforce part of a ship superstructure prone to fatigue-induced cracking. This project also provided an opportunity to demonstrate in-service, long-term durability of a composite reinforcement bonded to a metal structure. The aluminium superstructure on an Adelaide Class (FFG) frigate was reinforced using an adhesively bonded carbon fibre composite material. All aspects of the project undertaken by a DSTO team of researches from project inception in the late 1980s are described, including analysis of the superstructure cracking problem, research and development work, installation of composite reinforcement on board the ship, assessment of reinforcement efficiency, through-life monitoring and maintenance and repair. The original composite reinforcement is still in place on board HMAS SYDNEY. Further improvements in the technology have been made since, taking into account the new materials and processes which comply with the current occupational health and safety requirements.
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