america’s energy relies on dura-bond › wp-content › uploads › 2020 › 05 › dura...steel...
TRANSCRIPT
-
AMERICA’S ENERGY RELIES ON DURA-BONDSteel pipe manufacturing, protective coatings, steel fabrication
Dura-Bond was founded in 1960 by J.M. Norris to provide corrosion
protection services for manufacturers and users of steel products.
Today, Dura-Bond Industries operates four plants strategically
located in Western Pennsylvania’s Marcellus/Utica Shale Region.
The facilities utilize advanced steel manufacturing and protective
coating technologies.
Each plant, unique in its capabilities, complements the others by
enabling Dura-Bond to serve a wide range of customer-specific
requirements for steel pipe, protective pipe coatings and fabricated
steel products. Though each plant utilizes distinct processes to
expand our product offerings, they all share Dura-Bond’s trademark
reputation for quality, safety and excellent customer service.
Through the years, Dura-Bond has invested heavily in its facilities
to add innovative new processes and enhance proven techniques
and equipment. These investments provide our customers with
the high degree of quality and services they have come to expect
from Dura-Bond Industries.
DURA-BOND SIGNATURE EVENTSDura-Bond is a successful business built upon the proud accomplishments of three generations of
Norris family members and our experienced team of pipe manufacturing, steel fabrication and
corrosion protection professionals.
n 1980: Acquired Greensboro, NC facility
n 1982: Acquired 10.7 miles of Conrail track and created a short-line railroad
n 1983: Acquired pipe coating mill in McKeesport, PA
n 1985: Acquired steel fabricating plant in Jacksonville, FL
n 1993: Acquired pipe coating facility in Steelton, PA
n 2003: Acquired former Bethlehem Steel Corp LSAW pipe plant in Steelton, PA
n 2013: Opened FBE pipe coating facility in Duquesne, PA
n 2016: Acquired former US Steel McKeesport Tubular ERW pipe operations
-
LONGITUDINAL SUBMERGED ARC WELD (LSAW) PIPE
24” - 42” diameter, up to 80’ length
LSAW pipe manufacturing utilizes both external and internal
longitudinal submerged arc welding to produce a high-quality straight
seam weld that is unmatched in reliability and integrity. UOE pipe cold
forming begins with flat plates being side crimped, pressed to a U and
O shape, welded and hydraulically expanded. The forming and welding
processes maintain the integrity of steel plate’s unique properties and
assure performance specifications are satisfied.
Dura-Bond hydraulically expands each piece of LSAW pipe to ensure
exact body size and roundness. The pipe is pressurized with water until
the steel reaches specified yield strength. It is then forced against a steel
die for uniform final shape and diameter. The expansion also allows for
each pipe’s yield strength to be monitored and recorded.
Our unique hydraulic expansion process assures even dimensions
throughout the pipe. This is especially important when making field
cuts and fitting up the cut ends. Additionally, over-pressurization
exposes any weakness in the product’s long seam weld and body.
Most importantly, since the pressure is known at the point where the
pipe starts to yield, Dura-Bond can determine if the yield strength of
each joint of pipe meets the production specification, unlike other mill’s
random testing.
LSAW straight seam welding produces less weld per lineal foot than
spiral welded pipe, minimizing opportunities for weld related issues.
AMERICAN-MADE STEEL PIPE: ENERGY and UTILITY MARKETS
Quality steel pipe in grades up to X80
Dura-Bond’s Steelton plant manufactures large diameter longitudinal
submerged arc weld (LSAW ) pipe (24”-42”) for oil, gas and water markets.
Our API approved manufacturing processes and operation meet the
pipeline industry’s highest standards for American-made steel pipe quality.
Dura-Bond manufacturing systems employ the tubular industry’s most
advanced welding, pipe mill tracking and non-destructive testing. The
Steelton pipe mill is recognized industry-wide for quality, safety and
excellent customer service.
Dura-Bond operated as an on-site coater for Bethlehem Steel since 1993.
After idling pipe making operations in 1998, the former Bethlehem Steel
Corp pipe manufacturing facility was purchased and newly reopened by
Dura-Bond. Today, this unique Dura-Bond mill is producing API certified
steel pipe for some of North America’s largest pipeline projects.
Dura-Bond has invested heavily in the Steelton facility to add innovative
new processes and enhance proven techniques and equipment. These
investments provide our customers with the high degree of quality and
services they have come to expect from Dura-Bond.
INSIDE WELDERS BEVELER DOUBLE JOINING WELDING DOUBLE JOINING BEVELINGEXPANDER ULTRASONIC INSPECTION O PRESS OUTSIDE WELDERS VISUAL INSPECTION PLANER CRIMPER U PRESS
DURA-BOND LSAW STEEL PIPE PROCESS
America’s Energy Relies on Dura-Bond
-
DURA-BOND ELECTRIC RESISTANCE WELDED (ERW) PIPE
(8” - 20” diameter, up to 80’ length)
Dura-Bond Pipe McKeesport manufactures ERW steel pipe at our McKeesport,
Pennsylvania facility. The McKeesport plant sits on the site of the original
National Tube Works, which was later operated by US Steel.
This 317,000 square foot plant has been modernized to accommodate the
most technically advanced ERW processes. Dura-Bond also updated plant
logistics with the improvement of rail and road connections. Pipe coating
services are offered within close proximity at neighboring Duquesne, PA.
Dura-Bond’s API certified ERW line pipe is a tubular product produced by
continuously forming flat steel and welding the longitudinal seam using
high-frequency electric resistance welding.
Domestically manufactured steel coil is conditioned and prepped for welding
before passing through a series of cold-forming rolls that transform it from
flat steel to a round pipe section.
A high-frequency welder heats the edges of the rolled strip and pressure
rollers then squeeze the heated edges together to form a fusion weld. Every
weld is ultrasonically inspected to assure integrity and precise adherence to
API and ASTM specifications.
Next, the pipe is heat-treated to remove welding stresses and produce
a uniform normalized grain structure. It is then cooled and sent to the
sizing mill, where rollers straighten the pipe and size it to the correct
outside diameter.
As the continuous length of pipe moves toward the mill’s exit, a flying cut-
off slices lengths of pipe to manageable sizes without interrupting the
production flow. Each pipe is hydrostatic tested to ensure rated strength
and weld integrity under pressure.
Finally, the weld is ultrasonically inspected and the pipe body is fully
examined by automated electromagnetic inspection equipment. Customer
identity and project information is stenciled on each pipe.
CHARACTERISTICS AND ADVANTAGES
Eighty Foot Lengths – Ultra-long lengths
of Dura-Bond ERW pipe minimize handling
time during transportation and installation,
significantly reducing field welding labor, time
and costs.
High Quality ERW Pipe – Domestically manufactured
coil is fused by high frequency electric resistance
welders into rugged pipe that meet exacting
tolerances and strength specifications.
Uniform Dimensions and Quality – Continuous
non-destructive and visual inspection is
combined with state-of-the-art hydrostatic
testing to assure the manufacture of uniform
pipe that meet the highest quality standards.
DURA-BOND ERW STEEL PIPE PROCESS FBE COATING
1) COIL FEED RAMP 2) FIRST FORMING SECTION 3) FIN PASS SECTION 4) HIGH FREQUENCY WELDER 5) UT INSPECTION 6) ANNEALER 7) SIZING MILL
8) FLYING CUTOFF 9) HYDROSTATIC TESTING 10) STRAIGHTENING 13) FACING AND BEVELING12) CUT-OFF FACILITIES 14) FINAL INSPECTION and SHIPPING11) PHASED ARRAY UT
America’s Energy Relies on Dura-Bond
-
DURA-BOND COATING SYSTEMS
Dura-Bond’s plant-applied fusion bond epoxy pipe coating operations
can accommodate diameters ranging from 4” to 42” and lengths up to 80’.
Specialty coatings can be applied on 4” to 92” diameter pipe.
Fusion Bond Epoxy Coatings (FBE)
Fusion Bond Epoxy (FBE) is an environmentally-safe thermosetting
coating that is sprayed onto the pipe surface after it has been cleaned
and heated to over 450º F. Epoxy powder melts onto the steel surface
and fuses to the pipe, creating a hard barrier. Dura-Bond’s FBE coating
has been laboratory and field-tested to assure customers of field-
proven protection that will last for generations.
Abrasion Resistant Overcoating (ARO)
Our FBE Dual Coating System is a hard, mechanically strong overcoating
for use on top of any brand of fusion bond epoxy coatings. ARO
coating enhances the performance of the first layer of FBE corrosion
protection. It is applied to the base coating to form a tough outer
layer that is resistant to gouge, impact, abrasion and penetration.
This coating is specifically designed to protect the primary corrosion
coating from damage during pipeline directional drilling, bores, river
crossing and installation in rough terrain.
Internal Diameter Coating (ID Lining)
Dura-Bond applies internal coatings for uses ranging from water/
wastewater treatment to mainline gas transmission. The application of
internal diameter coating adds corrosion protection and increases flow
efficiency to the inside of steel line pipe. Dura-Bond can provide high
performance specialty linings that meet MIL-C-4556E military specifications
for use on pipelines that transfer jet fuel.
SPECIALTY COATINGS
Dual Layer
Dura-Bond offers dual layer FBE coatings for use in the most critical pipeline
environments. Our plants utilize a modern dual powder application booth
to keep both layers separated for maximum performance. Dura-Bond’s
advanced equipment and processes can apply any brand of fusion bond
epoxy and satisfy the most demanding specifications. Our dual layer
coatings provide abrasion resistance during pipeline installation, improve
cathodic protection and are ideal for use in rough terrain.
Powercrete®
Powercrete® is the pipeline industry’s most specified concrete overcoating
and Dura-Bond is North America’s leading applicator of this field-proven
abrasion protection. Dura-Bond and Powercrete® can provide superior
adhesion and abrasion resistance for below ground and submerged
pipelines. Powercrete® is impervious to soil stress and is fully compatible with
FBE. This tough plural component epoxy concrete is sprayed hot over freshly
applied FBE coating in a thickness of 20 to 125 mils. It is recommended for
use on pipe that is to be pulled under a river, road or wetland area through
a directional bore.
Liquid Epoxy
Dura-Bond applies NSF epoxy linings to the inside diameter of pipelines
that are required for sanitary applications and exterior liquid epoxy
coatings for exterior protection.
FBE is applied to 36 inch pipe at Dura-Bond Coating, Duquesene.
America’s Energy Relies on Dura-Bond
-
QUALITY ASSURANCE
Dura-Bond’s quality policy and objectives are fully endorsed by the
top management and reflect the commitment of its employees
to performance excellence. Dura-Bond Industries is committed to
achieving customer satisfaction by supplying quality pipe products
and services. To achieve this goal, Dura-Bond will manage its
business activities to:
n Build a work environment and work force focused on safety,
customer needs, and cost-effectiveness.
n Manufacture pipe and provide coating services meeting agreed
requirements, specifications, and standards.
n Continually improve quality through analysis and review of
processes and suppliers, and involving employees in development of
innovative solutions.
SAFETY INITIATIVE
The Dura-Bond Safety Initiative declares that all workplace accidents
are preventable. Our team pulls together to create a high level of
safety awareness in our work environment. Dura-Bond maintains
a safety development program that encourages manufacturing
exceptionalism. This company-wide initiative places the focus
squarely on safety and quality.
LOGISTICS
Dura-Bond can accommodate truck, rail and barge transport from our
conveniently located Pennsylvania facilities. Our access to interstate
highways, heavy haul rail lines and navigable waterways create unique
opportunities to match logistics to each customer’s preferable choice
of transport. Dura-Bond also maintains expansive pipe storage areas
where customer product can be staged for just-in-time delivery.
Promark Utility Supply n Test Stations
Polyken Tape Systems n Polyken Tape Products
STOPAQn Self Healing Coating
n Rehab Systems
n Outerwraps
Tinker and Rasorn Holiday Detectors
Powercrete®n Powercrete® R-95
n Powercrete® F-1
n Powercrete® J
Girard Industriesn Pipeline Pigging Products
3M Liquid Epoxyn 2 part Epoxy Sticks
n Liquid 2 part Epoxies
Delstar Technologiesn Rockshield
CCI Pipeline Systemsn Casing Spacers
n End Seals
DURA-BOND STEEL FABRICATION
Highway, Construction and Marine Fabricated Steel Pruducts
Dura-Bond is an A.I.S.C. certified steel fabricator specializing in
material for marine and heavy highway construction markets. We
fabricate complex steel structures, piling, wale systems, tie back
systems, soundwalls, retaining walls and railing systems for use in
highway and marine applications.
Our customers are assured Dura-Bond can meet the most exacting
specifications for the most complex projects. We back this assurance
with 30 years of experience and a list of satisfied customers that
includes the nation’s largest airports, seaports, energy companies
and utilities. Dura-Bond’s combined fabricating and coating
operations provide a timesaving advantage and reduce freight costs
with finished materials shipping from our on-site rail facilities.
A.I.S.C. Certified Steel Fabricator
The Dura-Bond facility in Export, Pennsylvania maintains over 60,000
square feet of manufacturing space and a lifting capacity of up
to 30 tons. This modern plant includes an A.I.S.C. approved paint
department capable of applying most liquid coating systems to
customer specified and customer provided material. Our Steelton
fabrication facility utilizes a 225,000 square foot workspace with up to
50 tons of lifting capacity and 60 acres of laydown/storage area.
Paint and Specialty Coatings
Dura-Bond applies protective paint and coating systems to structural
steel such as pipe piling, steel piling and H-Beams for the construction
market. We offer a complete line of coating options from coal tar
epoxy to specialized zinc/epoxy/urethane systems when high gloss
and color retention are a requirement.
Steel Fabrication Projects
n Single Span Bridges
n Piling Fabrication and Coating
n Waler Systems
n Sound Walls
n Retaining Soldier Pile Walls
n Railing Systems
n Walkways and Ramps
n Cofferdams
FIELD-PROVEN ENERGY AND UTILITY PIPELINE PRODUCTS
Dura-Bond offers the latest in pipeline products
for in-field installation, rehabilitation, storage and
post installation.
-
Dura- Bond Industries Corporate Headquarters
5790 KENNEDY AVENUE EXPORT, PA 15632 724-327-0280
Plant Capabilities
n Steel Fabrication n Custom Shapes Coatingn ID Lining n Powercrete® Coatings
Dura-Bond Coating Duquesne
5 NORTH LINDEN STREET DUQUESNE, PA 15110 412-436-2411
Plant Capabilities
n FBE/ARO Coating Applicator n Coated Pipe Storage
Dura-Bond Pipe McKeesport
301 4TH AVENUE MCKEESPORT, PA 15132 412-267-5840
Plant Capabilities
n ERW Pipe Manufacturer
Dura-Bond Pipe Steelton
2716 FRONT STREET STEELTON, PA 17113 717-986-1100
Plant Capabilities
n LSAW Pipe Manufacturern FBE/ARO Coating Applicatorn Steel Fabrication
dura-bond.com
Dura-Bond Industries, Inc. Dura-Bond was founded in 1960 by J.M. Norris to provide corrosion protection services for manufacturers and users of steel products. Today, Dura-Bond operates four plants strategically located in Western Pennsylvania’s Marcellus/Utica Shale Region. The facilities utilize advanced pipe manufacturing and protective coating technologies.