Oil, Gas & Petrochemical Structures

Pipe racks and modules offer significant savings through standardization. We rationalize bent spacing, tier elevations and member families so that a limited set of connection types covers most of the structure. Modularizing racks and skids moves labor from site to shop, improving quality and reducing time in hazardous areas. Early coordination of fireproofing extents also matters, because fireproofing weight and thickness affect member sizing, clearances and the overall structural program.

Members include rolled and built-up pipe rack bents, longitudinal struts, equipment support frames, modular skids, platforms, stairs and ladders. Welding procedures are qualified to the AWS D1.1 or EN 1090 execution class requirements specified, along with any additional owner requirements for material testing or weld procedure review. Modules are dimensionally controlled for piping fit-up and trial-assembled where interfaces are critical, and piece marks, module numbers and lifting points are clearly identified.

Oil and gas specifications usually require detailed documentation. We work to a project inspection and test plan with client witness and hold points, full material traceability from mill certificates to piece marks, NDT to the scope required for primary and critical welds, and dimensional reports for modules, anchor points and nozzle-sensitive supports. The QC dossier is compiled to the owner documentation index, ready for review and inclusion in the project handover records.

Process plants are often coastal or industrial environments with chemical exposure, so coating systems are typically selected for ISO 12944 C5 or CX categories using owner-approved paint systems. Galvanizing is common for platforms, gratings and secondary steel. Where structures are in hydrocarbon fire zones, we coordinate passive fire protection, such as cementitious or intumescent systems, with the fireproofing specification, ensuring compatibility with primers and detailing for application and inspection.

We plan packing and shipping to support modular and stick-built strategies alike. Modules and skids are prepared for lifting and sea-fastening with defined support points, while stick-built steel is bundled by rack section and erection zone. Bolts, gaskets and small items are packed by area. Shipments are documented with detailed packing lists, marking schedules and export paperwork aligned to the owner and EPC material management requirements.

We support erection contractors with erection drawings, module lift data and sequence planning that aligns with piping installation. Our engineers can provide input to method statements for heavy module lifts and temporary stability, and review set-down and tie-in details at site. Where agreed, we provide technical supervision or advisory visits during module installation, rack alignment and fireproofing interface checks.