
Novelty Steel fabricates carbon steel and stainless steel pipe spools for piping projects in its facilities in Turkey.
1. What is a Pipe Spool ?
Pipe spools refer to the pre-assembled piping components, encompassing pipes, flanges, and fittings. These elements are assembled during fabrication before being transported to the construction site. The pre-mounted state of these spools facilitates easy assembly using hoists, gauges, and other tools.
The spools connect long pipes with flanges at the ends which allows them to be securely bolted to another pipe. Before pouring the concrete, pipe spools are embedded into concrete walls to ensure proper positioning. This also allows to withstand the weight and force of the concrete.
In applications such as the construction of power plants and petroleum refineries, where extensive piping is essential for fluid and gas transport, the demand for efficient fabrication and assembly arises. Due to space constraints and the urgency to complete construction swiftly, these industries heavily rely on offsite fabrication and assembly. This involves two key stages: pipe spool production and site installation.
During pipe spool fabrication, a variety of raw pipes and fittings, including flanges, elbows, and tees, are employed. This fabrication occurs offsite. The raw pipes being pre-cut to specific sizes and temporarily fitted together with other components before undergoing welding.
The pipe spooling process is categorized into two main stages: spool roll fitting and welding. In roll fitting, a rolling machine turns the main pipe without requiring the fitter to change position, and spool permanent position fitting. Welding involves the fitter moving around the main pipe to complete the process. Welding tends to be a longer process compared to the roll fitting. Minimizing the number of spool position fitting and welding instances is a key objective in the sequencing of pipe spool fabrication.
2. Pipe Spool Materials
Depending on the application, pipe spooling can be done using these materials:
3. Advantages of Pipe Spooling
Construction companies engaged in the development of facilities with intricate pipe networks find several benefits in employing pipe spooling. Here are some of the pipe spooling:
Advantage | Description |
---|---|
Ease of Installation | Reduce on-site assembly time, simplifying installation and minimizing labor costs. |
Precision and Quality | Manufactured in controlled environments, ensuring high-quality welding, alignment, and dimensional accuracy. |
Time Efficiency | Off-site fabrication allows parallel construction activities, reducing project timelines. |
Customization | Can be tailored to fit specific project requirements, accommodating unique layouts and configurations. |
Reduced Waste | Pre-engineering and fabrication help minimize material waste and errors during construction. |
Improved Safety | Off-site fabrication reduces on-site work, lowering the risks associated with fabrication in the field. |
The use of pipe spooling allows the creation of complex systems through sophisticated and demanding processes. It is often not feasible to achieve similar quality results in on-site conditions.
4. Pipe Spool Fabrication
The fabrication of pipe is the bending, cutting, forming, and welding of individual pipe lengths and piping components to each other.
Carbon steel is the most commonly used material of construction used for process piping systems, followed by stainless steel and various alloys. Many nonmetallic materials also are used.
Material are selected according to their corrosion resistance to the fluid and ability to handle the design temperature and design pressure. Also considering environment and service conditions are critical in material selection.
The material used for fabrication must conform to a relevant ASTM, API, or other recognized standards
The major fabrication steps are;
The primary fabrication process, predominantly applicable to pipe lengths, is a fundamental step in the construction workflow. This is particularly true for pipes, as fittings come in standard dimensions. The cutting techniques commonly employed in this process are either mechanical or thermal. Mechanical methods, referred to as cold cuts, employ tools such as saws, abrasive discs, and specialized pipe cutting machines. On the other hand, thermal methods, also known as hot cuts, involve flame cutting utilizing either gas or electric arc cutting.

Photo 1: pipe cutting
Upon cutting a pipe to length, the end of the pipe is positioned at a 90-degree angle to the axis of the pipe for preparation before welding can start. Bevelling is the essential process employed to shape the end of a pipe correctly. It enables a seamlessly connection to another pipe or piping component to create a groove suitable for welding.

Photo 2 : Pipe Beveling
Forming in piping fabrication covers various techniques such as bending, extruding, swaging, lapping, and expanding, all aimed at creating a component for a connection.
While the standardization of welded pipe fittings has reduced the necessity for this fabrication process, it remains an option permitted by ASME B31.3.
Cold or hot bending of straight pipes presents an alternative and more frequently employed fabrication method compared to forming. Small-bore piping, typically less than 2″ in diameter for utility services, can be bent using an approved procedure. Additionally, large pipelines that need to be pigged for cleaning or batching purposes necessitate long-radius bends, often three to five times the outside diameter, to ensure a smooth passage for the pig. Such bends can be achieved through the bending of pipes.
When considering pipe bending, three critical dimensional limitations must be carefully addressed;
- Thinning
- Buckling
- Ovality
A comprehensive bending procedure is essential, and an appropriate bending method should be selected to manage these factors effectively.
Thinning is a crucial consideration because, during the bending process, the outer edge undergoes stretching, while the inner edge experiences compression. This stretching results in a thinning of the wall thickness in the outer section, and it must be closely monitored to ensure it does not exceed the allowable tolerance for the pipe.
Buckling is also a significant concern, as the bending operation has an opposing effect on the inner wall thickness, tending to compress it. However, this compression doesn’t always lead to thickening of the wall section. There is a tendency, at a certain stage of compression, for the inner edge to buckle.
Ovality is another key dimension to be mindful of because, during the bending process, the cross-section of the bend can take on an oval shape. The degree of ovality is determined by the difference between the major and minor axes divided by the nominal diameter of the pipe. Managing thinning, buckling, and ovality is crucial for ensuring the integrity and dimensional accuracy of the bent pipes.

Photo 3: Pipe Bending
Welding plays a pivotal role in the fabrication of process piping systems, emphasizing the necessity of employing correct procedures and qualified welders to ensure the integrity and reliability of the welded joints.
A well-defined Welding Procedure Specification (WPS) that clearly outlines the base metal, filler material, shielding fluxes/gases, positions, and heat treatment can result in a welded joint that possesses the necessary characteristics and is free from leaks. The specific parameters employed during welding are documented in a Procedure Qualification Record (PQR).
Fabrication tasks should be carried out by personnel who are qualified to work in accordance with the relevant Welding Procedure Specification (WPS). Following the guidelines set by ASME Section IX, a qualified welder who has not performed welding in a specific WPS within a specified period must undergo requalification. This ensures that the skills and qualifications of the welders remain up-to-date and in compliance with the established standards.
Defective welds requiring repair must be ground back to the base metal. The repair weld must adhere to the correct Welding Procedure Specification (WPS), considering that the contour surface may differ in profile and dimensions from the original. Preheating and heat treatment should match the specifications outlined for the original welding.
In both fabrication shops and site environment, two common types of welds are butt-weld and socket weld are used. However, due to the fabrication shop’s access to more equipment and a controlled environment, it is typically the preferred location for completing a weld, if possible.
The butt-weld requires special end preparations and can be applied to pipes of all commercial sizes. On the other hand, the socket weld is intended for use only on pipes up to NPS 4 (DIN 100)
Preheating before the welding process serves to decelerate the cooling rate of the weld joint. This deliberate slowing of cooling contributes to a heightened level of ductility in both the final weld and the heat-affected zone (HAZ). Preheating facilitates the more effective diffusion of dissolved hydrogen. It helps the reduction of shrinkage, distortion, and potential cracking induced by residual stresses in the welded structure.

Photo 4: Pipe Welding
5. Pipe Spool Applications
Industry | Application | Description |
Oil and Gas | Transportation Pipelines | Carrying crude oil, natural gas, and refined products over long distances. |
Refineries and Processing Plants | Handling high-pressure and high-temperature fluids during refining and chemical processing. | |
Offshore Platforms | Withstanding corrosive marine environments in subsea and topside piping systems. | |
Power Generation | Steam Systems | Transporting steam in boilers, turbines, and condensers. |
Cooling Water Systems | Carrying water to and from cooling towers. | |
Gas and Coal Plant Piping | Managing fuel supply and exhaust systems in power plants. | |
Chemical & Petrochemical | Process Pipelines | Transporting corrosive, hazardous, and high-pressure fluids. |
Reactor Systems | Ensuring precise connections for reactors and heat exchangers. | |
Safety and Control Systems | Containing and safely moving volatile substances. | |
Construction | HVAC Systems | Facilitating heating, ventilation, and air conditioning in buildings. |
Plumbing Systems | Ensuring reliable water supply and drainage networks. | |
Fire Protection Systems | Supporting sprinkler systems for fire suppression in high-rise buildings. | |
Food and Beverage | Fluid Transport | Moving liquid ingredients such as milk, oils, and syrups. |
Steam Systems | Carrying steam for sterilization and heating processes. | |
Clean-in-Place (CIP) Systems | Facilitating automated cleaning to maintain sanitary conditions. | |
Pharmaceutical | Sterile Piping Systems | Transporting purified water, clean steam, and critical fluids. |
Process Equipment Integration | Connecting reactors, mixers, and storage tanks with precision. | |
Water & Wastewater Treatment | Water Supply Networks | Transporting treated water to distribution systems. |
Wastewater Systems | Handling sewage and industrial effluents. | |
Desalination Plants | Managing the flow of seawater and brine in desalination processes. | |
Mining & Mineral Processing | Slurry Pipelines | Transporting abrasive mixtures of minerals and water. |
Process Water Systems | Carrying water for mineral washing and processing. | |
Chemical Transport | Moving reagents like acids and leaching agents. | |
Marine & Shipbuilding | Ballast Systems | Transporting water for ship stabilization. |
Fuel and Oil Pipelines | Handling fuel delivery in engine rooms. | |
Seawater Systems | Managing cooling, desalination, and firefighting systems. | |
Renewable Energy | Hydropower Plants | Transporting water in penstocks and turbines. |
Solar Thermal Systems | Carrying heat-transfer fluids in concentrated solar power setups. | |
Bioenergy Plants | Managing fluid systems in biogas and biofuel production. | |
Industrial Manufacturing | Compressed Air Systems | Powering tools and machinery. |
Process Cooling and Heating | Managing thermal requirements in production lines. |
6. FAQ
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.