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Before we dive into the production process, it's helpful to first understand the fundamentals of steel pipes.
In this article, we’ll explore the full and structured process of steel pipe manufacturing from selecting premium-grade steel coils, through advanced welding stages, protective coating, and finally packaging. All steps are carried out under strict quality control in accordance with national and international standards.
1. Steel Coil Inspection as Primary Material
The process begins by inspecting Hot Rolled Coils (HRC) and Hot Rolled Plates (HRP) to ensure compliance with chemical composition, thickness, and surface cleanliness. The selected material plays a critical role in the pipe’s strength and durability.
2. Coil Joining for Continuous Production
Each coil end is cleanly cut and welded to the next coil, allowing for uninterrupted production flow without needing to pause for reloading.
3. Leveling and Initial Ultrasonic Plate Inspection
The coil is leveled to ensure flatness, then tested using ultrasonic equipment (UT Plate) to detect any potential internal defects before forming.
4. Edge Scarfing and Side Trimming
Edges of the strip are trimmed and cleaned for precise and clean weld joints during pipe formation.
5. Pipe Forming
The steel strip is shaped into a cylindrical form through cold forming methods, ensuring dimensional precision and structural consistency.
6. Automated Welding
Welding is performed using one of three modern methods depending on project requirements:
- HFW / ERW (High Frequency Welding / Electric Resistance Welding)
- LSAW (Longitudinal Submerged Arc Welding)
- HSAW (Helical Submerged Arc Welding)
All methods produce strong, sealed, and high-pressure-resistant pipe seams.
7. Bead Removal (Inside and Outside)
Any internal or external weld beads are removed to create a smooth surface and ensure unobstructed flow.
8. Online Ultrasonic Seam Testing
Weld seams are tested in real time using ultrasonic systems to ensure they are free from defects during production.
9. Heat Treatment and Controlled Cooling
After welding, the pipe undergoes heat treatment to refine the metal structure, followed by controlled air or water cooling.
10. Sizing and Cutting
Each pipe is calibrated for exact diameter and straightness, then cut to required lengths—commonly 6 to 12 meters, or up to 64 meters for custom HSAW projects.
11. Dimensional and Initial Surface Inspection
The quality control team checks external dimensions, wall thickness, and surface condition to ensure conformity with production standards.
12. Flattening Test, Beveling, and Hydrotesting
- Flattening tests the pipe's ability to maintain form under vertical pressure
- Beveling shapes the pipe ends to prepare them for joining
- Hydrotest applies internal water pressure to verify leak integrity
13. Offline Ultrasonic Testing
Cut pipes are re-tested ultrasonically to ensure seam quality and the condition of each pipe’s ends.
14. Final Inspection and Product Marking
Final checks include dimension verification, visual and straightness assessments, coating thickness checks, bevel accuracy, and full labeling for traceability.
15. Protective Coating Process
Pipes are coated according to project needs, which may include:
- Temporary varnish
- Hot Dip Galvanizing
- Internal Cement Lining
- Epoxy Coating (internal or external)
- FBE (Fusion Bonded Epoxy), 3LPE (Three Layer Polyethylene) or 3LPP (Three Layer Polypropylene) for enhanced resistance to corrosion and harsh environments
16. Packaging and Delivery
Finished pipes are securely packaged to meet shipping standards and delivered to project sites across domestic and international locations.
From Plant to Project: Steel Pipe You Can Trust
With over 40 years of experience, Bakrie Pipe Industries delivers high-quality steel pipe products through a manufacturing process that is measurable, efficient, and internationally certified.
Looking for steel pipe solutions that are strong, precise, and built to last?
