- Optimize part design to minimize complex features.
- Choose readily available materials.
- Order larger quantities to lower the cost per unit.
- Use tolerances only as tight as necessary for functionality.
Modern CNC lathes with live tooling and multi-axis capabilities can handle complex geometries, including:
- Grooves and slots
- Undercuts
- Tapered or contoured surfaces
- Off-center holes
- 2-axis turning: Basic lathes for cylindrical and symmetrical parts.
- 3-axis turning: Adds a milling tool for additional features like slots or flat surfaces.
- Multi-axis turning: Combines turning and milling on multiple axes for complex, asymmetrical parts.
CNC turning can produce parts with varying surface finishes, such as:
- As-machined: Basic finish from the cutting tool.
- Polished: Smooth, reflective surfaces.
- Matte: Non-reflective surfaces.
- Bead blasting: For uniform textures.
- Anodizing or plating: For enhanced durability or aesthetics.
Yes, CNC turning can produce custom internal and external threads in both metric and imperial standards.
- Lathes: Standard CNC lathes for basic turning operations.
- Swiss-style Lathes: For small, intricate parts.
- Multi-axis CNC Turning Centers: Combine turning and milling for complex parts in a single setup.
Yes, many CNC turning services offer secondary processes, including:
- Polishing
- Anodizing
- Plating (e.g., chrome or zinc plating)
- Heat treatment
- Surface grinding
Pricing depends on factors like:
- Material type
- Part complexity
- Tolerances and surface finish requirements
- Quantity of parts
CNC turning is best suited for parts with rotational symmetry. However, features like grooves, threads, and complex contours can be added. Non-cylindrical designs may require additional CNC milling operations.
Turnaround time depends on the complexity of the part, quantity, and current workload. For simple parts, the lead time is usually 2-5 days, while complex or high-volume projects may take 1-2 weeks.
CNC turning is perfect for creating parts like:
- Cylindrical components
- Screws and bolts
- Shafts and rods
- Bushings and spacers
- Threaded components
- Custom fittings
Yes, we provide post-production assembly services, including mechanical assembly, fastening, and packaging, depending on your project’s needs.
If defective parts are identified, we will replace them free of charge. We work closely with our clients to address any issues promptly and improve future production runs.
Yes, to ensure manufacturability, consider the following:
- Avoid overly thin walls or deep pockets.
- Specify radii for inside corners.
- Use standard hole sizes where possible.
- Minimize excessive tolerances unless necessary.
Yes, our precision CNC machines are equipped to produce small, intricate components with features like micro-holes, fine threads, and detailed engravings.
Yes, we can combine CNC machining with other processes such as injection molding, die casting, 3D printing, and metal stamping for a complete manufacturing solution.
We ship globally using a variety of carriers. Depending on your location and urgency, we can provide standard shipping, expedited shipping, or freight options for large orders.
Yes. We can machine custom threads (both internal and external) and create specialized features such as undercuts, thin walls, deep pockets, and complex contours based on your specifications.
Yes, we have CNC machines capable of handling large parts and assemblies. Our facilities include machines with extended work envelopes and multi-axis capabilities to accommodate oversized or complex components.
Yes, we offer a variety of finishing services, including:
- Anodizing
- Powder coating
- Polishing
- Sandblasting
- Heat treatments
- Plating (e.g., chrome, nickel)
Lead times depend on project complexity, material availability, and order volume. Prototyping projects often take 1-3 weeks, while production runs may take 4-8 weeks. Expedited services are available for urgent needs.
Our facility utilizes a wide range of CNC machines, including:
- CNC mills
- CNC lathes
- 5-axis machining centers
- Swiss-style lathes
- CNC routers
Contract CNC machining refers to outsourcing precision manufacturing tasks to a specialized provider. These services involve computer-controlled machining processes to produce high-quality parts or components from various materials, including metals, plastics, and composites.
Aluminium’s high thermal conductivity can lead to distortion due to uneven heating.
Preventive Measures:
- Preheating: Reduces thermal gradients, especially for thicker sections.
- Clamping and Fixtures: Holds parts rigidly in place to minimize warping.
- Controlled Welding Speed: Adjusting travel speed and heat input to avoid excessive temperatures.
- Weld Sequencing: Alternating weld locations to balance stresses.
Surface defects can arise during handling, machining, or finishing.
| Defect | Cause | Solution |
| Scratches and Dents | Poor handling or inadequate protective measures. | Use protective films during transport and fabrication. |
| Porosity | Incomplete removal of oxides or contaminants during welding. | Clean thoroughly before welding and ensure proper shielding gas coverage. |
| Discoloration or Staining | Improper cleaning, exposure to moisture, or contamination. | Use anodizing or powder coating, and store aluminium in a dry, controlled environment. |
| Oxidation | Natural reaction of aluminium with air to form oxide layers. | While this is natural, it can be controlled with surface treatments like anodizing or painting. |
Quality control ensures that fabricated components meet the required specifications and tolerances. Key steps include:
- Dimensional Checks: Using calipers, micrometers, and coordinate measuring machines (CMM).
- Weld Inspections: Non-destructive testing (NDT) methods like X-rays or ultrasonic testing to detect defects.
- Surface Finish Checks: Ensuring consistent finishes, thickness of coatings, or anodizing layers.
Material Testing: Verifying properties like tensile strength and hardness using standardized tests (e.g., ASTM standards).
- 1xxx Series: Pure aluminium (99 %+), excellent corrosion resistance, but low strength. Used for chemical tanks and electrical applications.
- 2xxx Series: Aluminium-copper alloys, high strength, but less corrosion resistant. Common in aerospace.
- 5xxx Series: Aluminium-magnesium alloys, excellent corrosion resistance and weldability. Common in marine and automotive.
- 6xxx Series: Aluminium-magnesium-silicon alloys, good balance of strength, corrosion resistance, and machinability. Widely used in construction.
- 7xxx Series: Aluminium-zinc alloys, very high strength, used in aerospace and defence.
Aluminium fabrication is the process of shaping, forming, and assembling raw aluminium into finished components or products. It involves various techniques such as cutting, bending, welding, machining, and surface finishing to meet specific design requirements.
To prevent warping:
- Proper Welding Techniques: Use controlled heat input and alternate welds on opposite sides.
- Clamping: Secure the stainless steel firmly during welding or cutting.
- Cooling: Allow the material to cool naturally or apply controlled cooling methods.
- Stress Relief Treatments: After fabrication, stress-relieving processes can help minimize residual stress.
- Cold-Rolled Stainless Steel: Rolled at room temperature, it has a smooth surface, precise dimensions, and increased strength. It’s used for applications requiring tight tolerances and a polished finish.
- Hot-Rolled Stainless Steel: Rolled at high temperatures, it’s easier to form and is more cost-effective, but it has a rougher surface and less precision. It’s often used for structural or heavy-duty applications.
- Corrosion Resistance: Stainless steel is generally more corrosion-resistant than aluminum.
- Strength: Stainless steel is stronger and more durable but also heavier.
- Weight: Aluminum is lighter, making it ideal for applications where weight is a concern.
- Cost: Aluminum is typically less expensive but may require more maintenance over time.
- Applications: Aluminum is commonly used in lightweight structures, while stainless steel is preferred for strength, durability, and hygienic requirements.
Some challenges include:
- Work Hardening: Stainless steel tends to harden when worked, which can make cutting and forming more difficult.
- Thermal Expansion: It has a high rate of thermal expansion, which must be managed during welding to prevent warping.
- Corrosion during Fabrication: Improper handling, such as using contaminated tools, can introduce rust or surface damage.
- Precision Welding: Welding stainless steel requires precise temperature control to avoid overheating, discoloration, or weakening.
It depends on the type of stainless steel:
- Austenitic stainless steels (e.g., 304 and 316): Typically non-magnetic in their annealed state but can become slightly magnetic after cold working.
- Ferritic and Martensitic stainless steels (e.g., 430 and 410): Magnetic due to their higher iron content and crystalline structure.
Yes, while stainless steel is often used for its natural appearance, it can be painted or coated for additional protection or aesthetic purposes. Common coatings include:
- Powder Coating: Adds color and enhances durability.
- PVD (Physical Vapor Deposition): Adds decorative colors like gold, black, or bronze while retaining stainless steel’s durability.
- Epoxy Coatings: Used in harsh environments for additional corrosion protection.
- MIG (Metal Inert Gas) welding: Faster and easier to learn, MIG welding is commonly used for thicker pieces of stainless steel and high-production environments. It requires a continuous wire feed and uses a shielding gas.
- TIG (Tungsten Inert Gas) welding: Provides more precise and cleaner welds, making it ideal for thinner stainless steel. It requires more skill but offers superior control, especially for intricate or high-quality applications.
- Corrosion Resistance: Stainless steel is much more resistant to rust, corrosion, and staining compared to other metals like carbon steel or aluminum.
- Non-reactive: It doesn’t react with food, beverages, or chemicals, making it perfect for medical, food, and beverage industries.
- Long-lasting: Its durability ensures it lasts longer without the need for frequent replacement or repairs.
Stainless steel fabrication refers to the process of creating stainless steel structures, components, or products by cutting, bending, welding, and assembling various pieces of stainless steel material. It’s commonly used in industries like construction, food processing, aerospace, and automotive due to stainless steel’s durability, corrosion resistance, and aesthetic appeal.
Yes, we offer powder coating as optional finishing services to protect your project from corrosion and enhance its appearance.
Yes, in addition to welding, we provide:
- Metal Cutting
- Bending and Forming
- Drilling and Machining
- Assembly and Finishing
We follow strict quality control procedures, including:
- Using certified materials and consumables
- Conducting thorough inspections before, during, and after welding
- Employing experienced, certified welders with advanced training
Yes, we provide structural welding services for buildings, bridges, and other infrastructure projects. Our team ensures that all welds meet the necessary structural integrity and safety standards.
Yes, we have the expertise and equipment to handle large-scale industrial welding projects. Contact us to discuss your requirements, and we’ll provide a customized solution.
Yes, we offer finishing services such as grinding, polishing, and painting to ensure your project looks professional and is protected against rust and corrosion.
Yes, all our welders are certified. We prioritize safety and quality in every project.
Absolutely! We specialize in custom welding and fabrication projects. Whether you need a unique design, prototype, or specialized repair, our experienced welders can help bring your vision to life.
While Hardox grades share similarities, they are optimized for different tasks. Using the wrong grade can result in:
- Reduced lifespan: Using Hardox 400 where Hardox 500 is needed may lead to premature wear.
- Higher costs: Using Hardox 500 where Hardox 400 suffices might be unnecessary and increase expenses.
- Structural failure: Choosing Hardox 600 for impact-heavy applications could result in cracking.
Thicker plates of Hardox steel naturally become less tough due to the increased hardness. For example:
- Hardox 400: Works well even in thicker sections.
- Hardox 500/600: Recommended for thinner plates or where impact stresses are minimal.
- Hardox 450 has higher wear resistance (450 HBW vs. 400 HBW) and is slightly harder, making it suitable for applications where components face higher levels of abrasion.
- Hardox 400, while slightly softer, offers better machinability and toughness, making it easier to fabricate and weld.
- Hardox 500: Balances wear resistance with moderate toughness, making it suitable for heavy-duty applications like crushers and mining buckets.
- Hardox 600: Prioritizes extreme wear resistance at the cost of reduced toughness. It is ideal for environments with little to no impact stress but intense abrasion.
Welding Hardox steel requires care, especially for higher hardness grades. Key guidelines include:
- Preheating: Required for grades 500 and above to reduce the risk of cracking.
- Controlled Cooling: Avoid rapid cooling after welding to maintain structural integrity.
- Matching Electrodes: Use electrodes or filler materials designed for AR steels.
- Avoid Overheating: Excessive heat can reduce hardness in the heat-affected zone (HAZ).
| Grade | Applications |
| Hardox 400 | Dump truck bodies, conveyors, wear liners, bins, silos, chutes, and hoppers. |
| Hardox 450 | Loader buckets, cutting edges, crushers, containers, and concrete mixers. |
| Hardox 500 | Crushers, screens, wear plates, buckets for heavy-duty excavators. |
| Hardox 550 | Cement plants, coal chutes, sand slingers, and hammers. |
| Hardox 600 | Extreme abrasion environments like mining blades, extreme wear liners, and fans. |
| Hardox HiTuf | Structural applications, such as components for heavy machinery or bridges. |
Your choice depends on the application requirements:
- For moderate wear and impact: Hardox 400 or 450.
- For high wear with minimal impact: Hardox 500 or 550/600.
- For structural applications with high toughness needs: Hardox HiTuf.
When choosing between Hardox grades, consider these factors:
- Wear Resistance: Higher grades like Hardox 500/600 offer superior resistance to abrasive wear.
- Toughness: Grades like Hardox 400 or HiTuf have better toughness, making them suitable for impact-heavy environments.
- Weldability and Machinability: Lower grades (e.g., Hardox 400) are easier to work with, while higher grades may require specialized techniques.
- Thickness: Thickness influences the balance of toughness and hardness. Thicker plates may demand lower hardness to maintain structural integrity.
- Cost: Higher hardness grades generally cost more due to their advanced processing.
- Application: Match the grade to your specific application—e.g., mining buckets require high abrasion resistance (Hardox 500), while truck bodies may use Hardox 400 or 450.
Novelty Structures offer customized Hardox solutions, such as tailored plate dimensions and coatings. Specific grades like Hardox Extreme are also available for niche applications requiring ultra-high hardness.
The performance of Hardox steel depends on its thickness:
- Thinner plates tend to retain higher toughness.
- For thicker plates, you may need to select a lower hardness grade to maintain adequate ductility.
Yes, all Hardox grades can be welded and machined. However:
- Higher grades like Hardox 500/600 require preheating and specialized tools due to their higher hardness.
- Hardox HiTuf is easier to work with because of its lower hardness.
Hardox HiTuf prioritizes impact toughness over extreme hardness. It is ideal for applications that experience heavy impact loads and where cracking or brittleness must be avoided.
While Hardox steel is primarily designed for wear resistance, it can be treated with protective coatings to enhance its resistance to corrosion, especially in environments with high moisture or chemicals.
High-strength tools are recommended:
- Drilling and Milling: Use carbide or cobalt-tipped tools.
- Cutting: Plasma, laser, or oxy-fuel methods are most efficient.
- Forming: Requires proper equipment and following bending guidelines for optimal results.
Yes, Hardox steel maintains its toughness and impact resistance even in very low temperatures, making it suitable for cold environments like Arctic mining operations.
Hardox steel is produced through a controlled rolling process, which results in a fine-grained microstructure. This microstructure contributes to its exceptional wear resistance and toughness.
Hardox steel stands out because of its consistent quality, proven durability, and versatility.
Delivery time depends on the grade, thickness and dimensions
Yes! Hardox steel can be customized through cutting, machining, and processing to meet your unique requirements.
Hardox steel offers superior hardness, toughness, and wear resistance compared to standard steel. This means longer service life, reduced maintenance, and better performance under challenging conditions.
Hardox steel is available in a wide range of thicknesses, from 2 mm (for lightweight applications) to over 100 mm (for heavy-duty uses).
The choice of grade depends on your specific application:
- For general wear resistance, choose Hardox 400 or 450.
- For extreme wear conditions, opt for Hardox 500 or 600.
- For structural components under heavy impact, Hardox HiTuf is ideal.
Hardox steel combines hardness, toughness, and flexibility, making it ideal for heavy-duty applications. It resists wear, handles impact without cracking, and can be machined, cut, or welded like regular steel.
Yes, aluminium trusses are suitable for both temporary and permanent installations. For permanent use, ensure they are securely anchored and comply with local building codes and regulations.
Thanks to their lightweight nature, aluminium trusses are easy to transport. They often come in modular sections that can be stacked or packaged efficiently for shipping.
With proper maintenance and care, aluminium truss systems can last for decades. Their corrosion-resistant properties and robust construction ensure long-term durability.
Yes, circular and custom trusses are specifically designed for unique shapes, including curves, spirals, and other geometric designs. This flexibility makes them a popular choice for creative architectural and event setups.
Yes, aluminium truss systems are safe when used correctly. Ensure proper assembly, adhere to the manufacturer’s load capacity guidelines, and conduct regular inspections for optimal safety.
To maintain your aluminium truss system:
- Regularly inspect for damage, wear, or corrosion.
- Ensure bolts, clamps, and joints are securely tightened.
- Clean with mild soap and water to remove dirt and grime.
- Store in a dry, protected area when not in use.
Aluminium truss systems are designed for quick and straightforward assembly and disassembly. Many systems use modular components with connectors, clamps, or bolts for easy setup, making them ideal for temporary installations like events or trade shows.
Absolutely. Aluminium trusses can be customized in terms of size, shape, color, and finish. Powder-coating, anodizing, or adding branding elements are common customization options.
Yes, aluminium trusses are naturally corrosion-resistant, making them suitable for outdoor use. However, additional protective coatings or treatments can enhance their durability in harsh weather conditions.
The weight capacity of an aluminium truss system depends on its design, size, and configuration. Manufacturers typically provide load charts and specifications to help determine the appropriate system for your needs.
To select the right truss system:
- Determine the weight and type of load the truss will support.
- Assess the environment where it will be used (indoor, outdoor, or both).
- Evaluate modularity and ease of assembly for your project.
- Consider aesthetic and branding requirements.
- Consult with a reputable supplier or manufacturer for expert advice.
An aluminium truss system is a lightweight, durable framework used for structural and aesthetic purposes. It is composed of interconnected aluminium components, typically in a triangular design, to provide stability and support for various loads.
We understand that project requirements may evolve. Our team maintains clear communication and flexibility to accommodate changes, ensuring minimal disruption to timelines and budgets.
Yes, we specialize in modular steel structures that are pre-engineered and fabricated for quick on-site assembly. These are ideal for temporary or permanent installations like prefabricated buildings, shelters, or portable offices.
For large-scale projects, we follow a streamlined process that includes:
- Detailed project planning and scheduling
- Dedicated project managers
- Efficient material procurement
- Regular progress updates for clients
Yes, we have extensive experience in fabricating steel structures that are designed to withstand earthquakes, high winds, and other extreme conditions.
We provide logistics support, including safe packaging, transport, and delivery of fabricated steel components to your project site. We coordinate with reliable shipping providers to ensure timely and secure delivery.
We use advanced technologies like CNC (Computer Numerical Control) machines, laser cutting, and 3D modeling software to ensure precision and accuracy in every fabricated component.
Our team uses a range of welding techniques to suit different fabrication requirements, including:
- MIG (Metal Inert Gas) welding
- TIG (Tungsten Inert Gas) welding
- Arc welding
- Spot welding
Each method is chosen based on the project’s material, thickness, and strength requirements.
Yes, we offer a variety of steel finishing services to enhance durability, aesthetics, and resistance to corrosion. These include:
- Powder coating
- Galvanizing
- Painting
- Sandblasting and surface treatment
Yes, our facilities and team are equipped to handle projects of any size, from small-scale custom components to large industrial or commercial structures.
The cost varies based on factors such as material type, project size, design complexity, and additional services (e.g., installation). Contact us for a detailed quote.
We provide steel fabrication services locally, regionally, and internationally, depending on the project’s scope and logistics. Contact us to discuss your location.
The timeline for steel structure fabrication depends on factors such as project size, complexity, and customization requirements. Smaller projects may take a few weeks, while larger or more intricate projects could take several months.
Our services cover the fabrication of:
- Building frameworks
- Beams, columns, and trusses
- Stairs, handrails, and ladders
- Custom platforms and walkways
- Storage tanks and silos
- Bridges and structural components
Steel structure fabrication serves a wide range of industries, including:
- Construction (commercial and residential buildings, warehouses, etc.)
- Industrial (factories, refineries, and power plants)
- Transportation (bridges, rail infrastructure, etc.)
- Energy (oil and gas platforms, wind turbine structures)
- Agriculture (barns, silos, and equipment sheds)
Yes, we can fabricate trusses for temporary structures, such as:
- Event venues and stages.
- Exhibition halls.
- Temporary warehouses or storage units.
Our quality control process includes:
• Material Testing: Ensuring the steel meets required strength and grade specifications.
• Dimensional Accuracy: Verifying precision in cuts and welds.
• Load Testing: Simulating structural loads to confirm truss integrity.
• Final Inspection: Comprehensive checks before delivery.
We offer various coatings and finishes to suit different environments, including:
- Galvanization: For corrosion resistance.
- Powder Coating: For aesthetic and durable finishes.
- Epoxy Coatings: For industrial or marine environments.
- Priming and Painting: To match architectural preferences.
Yes, steel trusses are naturally fire-resistant. However, to enhance their performance in extreme heat, we offer fireproof coatings or can recommend additional fire protection measures.
The cost depends on:
- The type and quantity of steel used.
- Complexity and customization of the design.
- Additional finishes (e.g., galvanization, painting).
- Transportation and installation requirements.
We provide detailed quotes after reviewing your project needs.
The timeline depends on the project’s complexity, design requirements, and quantity. On average, small to medium-scale projects take 2–6 weeks, while large or custom projects may take longer. We provide detailed timelines during the consultation phase.
The process includes:
- Material Selection: Choosing the appropriate type of steel.
- Cutting and Welding: Shaping steel components and welding them together.
- Finishing: Applying protective coatings like paint or galvanization.
- Inspection and Delivery: Ensuring quality control and transporting the trusses to the site.
Yes, we specialize in custom steel truss fabrication. Our team works closely with engineers, architects, and clients to design trusses tailored to your project’s specifications, load requirements, and aesthetic preferences.
Steel trusses are widely used in various industries, including:
- Construction: Commercial and residential buildings, warehouses, and sports complexes.
- Infrastructure: Bridges, railway stations, and airports.
- Industrial: Factories, power plants, and storage facilities.
- Agricultural: Barns, greenhouses, and grain storage buildings.
Steel truss fabrication is the process of designing, manufacturing, and assembling steel structural frameworks. These frameworks, called trusses, are used to support roofs, bridges, towers, and other structures. The trusses consist of triangular units to provide stability and distribute loads effectively.
Yes, we can fabricate modular tanks that can be transported in sections and assembled on-site, ideal for large or remote projects.
Maintenance depends on the tank’s application and environment. Regular services include:
- Visual inspections for wear, corrosion, or damage
- Cleaning and sterilization (for food-grade or potable water tanks)
- Coating reapplication
- Leak detection and repair
Pricing varies depending on factors such as:
- Size and capacity
- Material selection (e.g., stainless steel vs. carbon steel)
- Custom features and complexity
- Required certifications and testing
We provide transparent quotes and work with clients to meet their budget.
Yes, we serve clients worldwide and coordinate international shipping for all tanks. Our logistics team ensures compliance with import/export regulations and proper handling during transit.
We maintain strict quality control processes throughout fabrication, including:
- Material testing and verification
- Welding inspections
- Hydrostatic and pressure testing
- Non-destructive testing (NDT)
- Final inspection and certification
Lead times vary depending on the complexity and size of the project. Generally, smaller tanks may take a few weeks, while larger or more complex tanks may require several months. We provide detailed timelines during the project planning phase.
We primarily use stainless steel and carbon steel, depending on the application and environmental conditions. Stainless steel is ideal for applications requiring corrosion resistance, while carbon steel is often used for its strength and cost-effectiveness.
Yes, our fabrication services are fully customizable. We can design tanks to meet your specific size, capacity, material, and industry standards. Our team works closely with clients to ensure all requirements are met, including compliance with regulatory codes.
We fabricate a variety of steel tanks, including:
- Vertical and horizontal storage tanks
- Pressure vessels
- Double-walled tanks
- Custom-designed tanks
- Stainless steel and carbon steel tanks
Yes, our advanced fabrication capabilities allow us to create pressure vessels with complex geometries, such as multi-compartment vessels, spherical shapes, or vessels with intricate internal components.
We maintain full traceability of materials used in fabrication, including:
- Heat numbers
- Material Test Certificates (MTCs)
- Welding records
- Inspection and testing reports
This ensures compliance with industry standards and customer specifications.
Yes, we work with international clients and are familiar with various global standards, including ASME, PED, and others. We also handle shipping and documentation for global logistics.
Yes, we can fabricate pressure vessels for mobile and skid-mounted systems. These designs are ideal for modular applications in industries like oil & gas, water treatment, and process manufacturing.
The cost depends on factors such as size, material, complexity, and required compliance standards. For an accurate estimate, please contact us with your project details.
Yes, all fabricated pressure vessels are delivered with complete documentation, including:
- Material Test Reports (MTRs)
- Welding Procedure Specifications (WPS)
- Quality Control Inspection Reports
- Certifications of Compliance
Lead times vary based on the complexity and size of the vessel. Simple designs may take 4–8 weeks, while larger, more complex projects can take 12–20 weeks or longer. We provide detailed timelines during the project planning phase.
We can fabricate pressure vessels of various sizes, ranging from small laboratory-scale vessels to large industrial tanks. Pressure ranges are tailored to customer needs and can go from low-pressure to high-pressure applications.
The process typically involves:
- Design and Engineering: Ensuring compliance with applicable codes and standards.
- Material Selection and Procurement: Choosing materials suited to the application.
- Cutting and Forming: Preparing plates, sheets, or other raw materials.
- Welding: Using methods such as MIG, TIG, or arc welding.
- Quality Control and Testing: Ensuring structural integrity via non-destructive testing (NDT), hydrostatic testing, and other methods.
- Final Assembly and Delivery.
Yes, we specialize in custom pressure vessel fabrication tailored to meet the exact specifications and needs of our clients. Our team works with your engineers to create solutions that are efficient and reliable.
We fabricate a variety of pressure vessels, such as:
- Storage Tanks
- Reactors
- Heat Exchangers
- Distillation Columns
- Air Receivers
- Custom-designed vessels for specific applications
Our fabrication services comply with internationally recognized standards, including:
- ASME Boiler and Pressure Vessel Code (BPVC): Section VIII
- API (American Petroleum Institute): Standards for specific industries
- PED (Pressure Equipment Directive): For European compliance
Pressure vessels are fabricated using various materials, including:
- Carbon Steel
- Stainless Steel
- Alloy Steels
- Aluminum
The choice of material depends on factors like temperature, pressure, and the chemical nature of the contents.
A pressure vessel is a container designed to hold gases or liquids at a pressure substantially different from the ambient pressure. They are widely used in industries such as oil & gas, chemical processing, power generation, and water treatment.
Novelty Structures accomodates scope changes, but these can affect timelines and costs. It’s important to establish clear project goals and communicate changes as early as possible.
Lead times depend on the complexity and scope of the project but typically range from 12 to 24 weeks. Early involvement of the client in the design phase helps streamline the process.
Costs vary widely based on size, complexity, materials, and customization. While initial costs may seem high, process skids often save money in the long run by reducing installation and operational expenses.
Process skids are designed for ease of transportation. They can be shipped as a single unit or broken down into smaller modular components for easier handling. We also ensure that skids comply with shipping and road transport regulations.
Key tests include:
- Factory Acceptance Testing (FAT) to simulate real-world operating conditions.
- Leak testing using hydrostatic or pneumatic methods.
- Instrument calibration and automation system validation.
Visual and dimensional inspections to ensure adherence to design specifications.
Common materials include carbon steel, stainless steel, duplex stainless steel, and high-performance alloys. The choice of material depends on the process conditions, such as temperature, pressure, and the chemical properties of the fluids being handled.
Process skids are designed to meet industry-specific standards, such as:
- ASME (American Society of Mechanical Engineers) for pressure vessels.
- API (American Petroleum Institute) standards for oil and gas.
- ISO certifications for international projects.
Yes, process skids are highly customizable. They can be designed to meet specific process requirements, space constraints, and industry standards. Engineers work closely with clients to ensure all performance, material, and safety needs are addressed.
Each fabricated heat exchanger comes with comprehensive documentation, including:
- Material Certificates: For all materials used in manufacturing, ensuring compliance with specifications.
- Test Reports: For pressure testing, thermal performance, and non-destructive testing (NDT) results.
- Quality Control Documentation: Detailing all inspections, measurements, and certifications that the heat exchanger has passed.
We offer warranties on the heat exchangers we fabricate. Warranty periods vary based on factors like material selection, design complexity, and application conditions. The warranty typically covers:
- Material defects
- Workmanship
- Performance issues (if the unit fails to meet agreed-upon specifications)
Specific warranty details are provided in the contract, ensuring full transparency and peace of mind.
Yes, we understand that client needs may evolve during the manufacturing process. We offer flexibility in design modifications, but changes may affect the overall timeline and cost. Any adjustments to the design will be discussed with you in detail to ensure alignment with your new requirements and to avoid delays.
We understand the importance of timely delivery, and we prioritize meeting deadlines for every project. To ensure this, we:
- Provide detailed project timelines and milestones from the start.
- Use advanced project management tools to track progress and stay on schedule.
- Maintain close communication with clients to address any concerns or changes promptly.
- Have streamlined production processes and established relationships with suppliers to avoid delays in material procurement.
The cost depends on various factors, including:
- Type of heat exchanger (shell and tube, plate, etc.)
- Materials used
- Design complexity
- Quantity ordered
- Testing and certifications required
We offer competitive pricing and will provide a detailed quote after understanding your specific requirements.
Yes, we have the capability to handle both small and large-volume production runs. Whether you need a single unit for a specialized application or a bulk order for industrial use, we can scale our manufacturing process to meet your needs.
Yes, we can fabricate heat exchangers using a variety of materials, depending on the application requirements, including:
- Stainless Steel
- Nickel Alloys
- Titanium
- Carbon Steel
We can also incorporate coatings and treatments to improve corrosion resistance and extend the lifespan of the heat exchanger.
The timeline for manufacturing depends on several factors, such as design complexity, material sourcing, and quantity. Generally, it can take from a few weeks to several months. We provide a detailed timeline after assessing the scope of the project and required specifications.
The time required to fabricate an industrial boiler can vary depending on its complexity, size, and customization. On average, fabrication can take anywhere from several weeks to several months. This includes design, material procurement, welding, assembly, pressure testing, and commissioning.
Safety is a major concern during boiler fabrication and operation. Key safety considerations include:
- Pressure Testing: Boilers must undergo rigorous pressure tests to ensure they can safely handle the required operating pressures.
- Welding and Structural Integrity: All welds must be inspected to ensure there are no defects that could lead to boiler failure.
- Code Compliance: Boilers must adhere to safety codes such as ASME (American Society of Mechanical Engineers) or EN (European Standards) for design, fabrication, and installation.
- Fire and Explosion Risk: Boilers should be designed to prevent the risk of explosion or fire by ensuring proper venting, combustion control, and flame supervision.
Yes, industrial boilers can be customized to meet the specific needs of different industries. Customizations may include size, fuel type, pressure, temperature, and additional features such as economizers or superheaters to enhance efficiency.
The lifespan of an industrial boiler can vary based on factors such as the type of boiler, the materials used, and how well it is maintained. Generally, industrial boilers can last between 20 to 40 years with proper care, though certain components may require replacement during that time to ensure continued performance.
Refractory materials are used to line the interior of a boiler’s combustion chamber and other areas exposed to high temperatures. They protect the boiler from heat damage, prevent heat loss, and enhance the overall thermal efficiency of the system.
Regular maintenance of industrial boilers involves:
- Inspection: Checking for signs of wear and tear, corrosion, and leaks.
- Cleaning: Removing scale and soot buildup that can affect efficiency.
- Pressure Testing: Ensuring the boiler operates within the specified pressure limits.
- Replacement of Parts: Replacing worn-out components such as valves, tubes, and seals.
- Monitoring: Continuously monitoring key parameters like temperature, pressure, and efficiency.
The main types of industrial boilers are:
- Fire Tube Boilers: Hot gases pass through tubes surrounded by water. Common in smaller applications.
- Water Tube Boilers: Water flows through tubes heated by the fire, used for high-pressure applications.
- Fluidized Bed Boilers: Used for burning various fuels efficiently and are typically found in power generation plants.
- Waste Heat Boilers: Designed to recover energy from exhaust gases.
Industrial boiler fabrication involves the design, manufacturing, and assembly of boilers that are used in industrial processes. It includes the selection of appropriate materials, welding, assembly of various components, and ensuring that the final product meets the necessary standards for pressure, temperature, and efficiency.
Changes in scope should be communicated immediately. We can accommodate adjustments, but this may impact timelines and costs. Collaborative planning and contingency allowances in the contract can help mitigate disruptions.
Pipe spools are typically labeled with unique identification numbers or tags that correspond to installation drawings. This labeling helps installers quickly match spools to their intended positions in the system. Fabricators also package spools securely to prevent damage during transport and may provide detailed packing lists for easy inventory management.
While prefabrication may have higher upfront costs compared to on-site fabrication, it typically reduces overall project expenses. Savings come from reduced on-site labor, minimized material waste, and faster installation. Additionally, controlled fabrication environments decrease the risk of costly errors and rework.
Key testing methods include hydrostatic testing to confirm pressure resistance, non-destructive testing (NDT) for weld and material integrity, and dimensional inspections to ensure precision. Some projects may require additional tests, such as X-ray examination of welds or corrosion-resistance testing.
Yes, pipe spools can be customized to meet specific requirements, such as unique dimensions, non-standard materials, or special connections. Fabricators can adjust designs and components to accommodate project-specific challenges, like tight installation spaces or extreme operating conditions.
A reliable fabricator should provide detailed documentation, including material certificates, weld inspection reports, dimensional verification records, and hydrostatic test results. They should also supply drawings, as-built records, and any required compliance certifications.
Lead times depend on the complexity and size of the project, material availability, and the fabricator’s capacity. Standard projects may take a few weeks, while large-scale or highly customized orders might require several months. Communicating your project schedule early helps align expectations and avoid delays.
Collaborate closely with the fabricator during the design phase to ensure all specifications are detailed and achievable. Request a fabrication plan and review engineering drawings. Insist on thorough quality assurance procedures, including inspection reports, material certifications, and compliance with relevant standards.
Pipe spools can be coated or finished with materials that protect against corrosion, abrasion, or chemical exposure. Options include epoxy coatings, galvanization, and thermal insulation layers. The choice depends on the operational environment, such as offshore settings, chemical plants, or high-temperature systems.
Pre-fabricated pipe spools significantly reduce on-site installation time, as the components arrive ready for assembly. This minimizes delays caused by weather, labor shortages, or on-site fabrication errors. By streamlining the installation phase, projects are more likely to stay on schedule and within budget.
When choosing a fabricator, evaluate their capacity, expertise, certifications. Check their track record for delivering projects on time and within budget, their capacity to handle large or custom orders, and the quality of their testing and inspection processes. Additionally, ensure they have a robust quality control program and the ability to provide detailed documentation and reports. Novelty Structures is an experienced contractor with varios reference projects spread all around the World.
To get started:
- Contact us via our contact page.
- Share your project details, including specifications, drawings, and timelines.
- Our team will evaluate your needs and provide a customized proposal and quote.
We provide piping fabrication services locally, nationally, and internationally. Our team can mobilize quickly to meet project requirements regardless of location.
Yes, we offer prefabricated piping solutions tailored to your specifications. Prefabrication ensures reduced installation time, improved accuracy, and cost savings for large-scale or repetitive projects.
Our team consists of highly qualified and certified professionals, including:
- Certified Welders
- Experienced Pipefitters and Engineers
- Quality Assurance Inspectors (NDT Level II & III Certified)
We continually train our staff to meet industry advancements and safety requirements.
Yes, we understand that some projects require rapid turnaround. With our advanced facilities and efficient workflows, we can expedite fabrication while maintaining quality standards. Please contact us to discuss your project’s timeline.
We perform a comprehensive range of inspections and tests, including:
- Non-Destructive Testing (NDT): Radiographic (X-ray), Ultrasonic, Magnetic Particle, and Dye Penetrant Testing.
- Hydrostatic and Pneumatic Testing: Ensures pipes can withstand pressure without leaks.
- Visual and Dimensional Inspections: To verify accuracy and quality.
- Material Certification Verification: Ensures the correct material grade and composition.
Yes, we are experienced in fabricating piping systems for demanding environments, including high-pressure and high-temperature conditions. Our fabrication processes and material selection ensure safety, strength, and reliability under extreme conditions.
Pipe spools are pre-fabricated pipe sections consisting of pipes, fittings, and flanges, created off-site for quicker on-site installation. Spools reduce labor costs, improve quality control, and save significant time during project execution.
We fabricate a wide range of pipes and fittings, including:
- Elbows (45°, 90°, and custom angles)
- Tees and Crosses
- Reducers (Concentric and Eccentric)
- Flanges (Slip-on, Weld Neck, Blind, etc.)
- Spools and Pipe Supports
- Custom-designed components
Key cost drivers include:
- Material type and quantity.
- Complexity of design and assembly.
- Quality testing requirements.
- Coating and surface treatment options.
- Shop Fabrication: Piping is fabricated in a controlled environment with access to advanced machinery and tools. It ensures higher precision and quality.
- On-Site Fabrication: Pipes are fabricated at the installation location, typically for large or complex projects where transportation is challenging.
Standard documentation includes:
- Material Test Reports (MTRs)
- Weld logs and maps
- Inspection and test records
- Pressure testing certificates
- Compliance certificates (e.g., ASME, API)
Project timelines vary based on complexity, material availability, and the scope of work. Simple systems may take a few weeks, while large, intricate systems can take months.
Welding quality is assured through:
- Certified welders using approved welding procedures (WPS).
- Visual inspections and advanced NDT methods to detect defects.
- Adherence to welding standards like ASME Section IX or ISO 15614.
Surface treatments improve the durability and performance of piping systems. Options include:
• Galvanizing
• Epoxy or polyurethane coating
• Sandblasting and painting
NDT is a testing method to evaluate the integrity of materials and welds without causing damage. It ensures the reliability of the piping system and includes methods like ultrasonic testing, radiography, and dye penetrant testing.
Material selection depends on factors like operating temperature, pressure, fluid type, and environmental conditions.
Pipe fabrication adheres to international standards for safety and quality. Commonly referenced standards include:
- ASME B31.1 (Power Piping) and ASME B31.3 (Process Piping)
- API 5L (Pipeline Standards)
- EN 13480 (Metallic Industrial Piping)
- ISO 15614 (Welding)
Yes, laser cutting is highly effective for prototyping. It allows engineers to quickly iterate designs, test functionality, and refine geometries with minimal lead time.
The cost depends on material type, thickness, project complexity, and production volume. While the initial setup may be higher, laser cutting often reduces overall costs due to precision and minimal material waste.
Laser cutting is generally non-contact, minimizing mechanical stress on materials. However, localized heat can cause slight thermal effects, such as discoloration or minor hardening, depending on the material.
Yes, laser cutting is suitable for both prototyping and high-volume production. Its repeatability ensures consistent results across large batches.
Lead times vary based on project complexity, material availability, and workload. For simple designs, lead times can be as short as 1–3 days, whereas complex projects may take longer.
Several factors influence the cutting results, including:
- Material type and thickness
- Laser power and focus
- Cutting speed
- Gas type and pressure used during the cutting process
- Proper maintenance of the equipment
Typical tolerances depend on the material and equipment but generally range from ±0.1 mm to ±0.2 mm. High-precision equipment may achieve even tighter tolerances.
While highly effective, laser cutting does have limitations:
- Material Thickness: Thicker materials may require higher power or slower speeds, which could increase costs.
- Reflective Materials: Some materials, like copper and brass, can reflect laser energy, making them harder to cut.
- Initial Costs: The machinery and setup costs are significant, though long-term savings often offset this.
Laser cutting works on a wide range of materials, including:
- Metals: Steel, aluminium, stainless steel, brass, copper.
- Non-metals: Plastics, wood, glass, acrylic, and composites.
Laser cutting is a manufacturing process that uses a high-powered laser beam to precisely cut, engrave, or shape materials. The laser beam is focused onto the material, melting, burning, or vaporizing it along a predefined path. This results in clean, accurate cuts with minimal material waste.
Our factories are located in Turkey. We both use sea and land freight for the delivery of our products.
We have various painting options based on the customer preferences and site environment. We also work with 3rd party galvanizers to offer hot dip galvanization.
We have in-house design engineers but we also manufacture based on client drawings. Just send us your project and let us work on a quotation.
Novelty Steel complies with European quality standards and certifies with EN 1090-2 standard. All the welders possess EN ISO 9606 Welding Certificate. All our fabrications are marked with CE mark.
Novelty Steel is equipped with various CNC machinery to automatize the fabrication process and deliver high quality. We have in-house fiber lasers, shear cutters, plate rollers, bending machines, steel profile drilling lines, shot blasting lines, mig/mag welding machines, airless painting machinery and various other equipment.
Although these two expressions are mostly used to define metal works, structural steel fabrication is usually referred to fabrications made out of structural steel sections whereas metal fabrication is used for the fabrication works of sheet metal.
Novelty Steel gained experience in using carbon steel (mild steel), hardox steel, stainless steel and aluminium in its fabrications.
The length of time to steel fabrication is dependent entirely on the project size, project requirements and client preferences. Our close proximity to steel mills is a great advantage to offer short lead times.
We have experienced in house engineers to assist you in your design phase. We generally do not charge for consultation and steel detailing prior to the fabrication. Early consulting to our engineers may prevent any design mistakes which may cost time and money later
