An Australia international and New South Wales State of Origin representative forward, he played for the Cronulla-Sutherland Sharks, Western Reds and the Melbourne Storm.

In March 1992, Kearns made his first grade debut for Cronulla-Sutherland Sharks in round 1 against the Brisbane Broncos at Lang Park, becoming a regular in the Cronulla side during the 1992 season.

[3] Having won the 1999 Premiership, the Melbourne Storm travelled to England to contest the 2000 World Club Challenge against Super League Champions St Helens R.F.C., with Kearns captaining at prop forward in the victory.

In 2000 Kearns was awarded the Australian Sports Medal for his contribution to Australia's international standing in rugby league.

He retired at the conclusion of the 2005 season after a 13-year career,[5][6] but remained with the Melbourne Storm in a marketing and business development capacity.