Steel Structures and Custom Fabrication for Petrochemical Projects

Levstal provides steel fabrication for petrochemical plants, manufacturing structural steelwork, equipment support structures and custom welded components for new construction, plant expansion, modernisation and maintenance projects.

We work with EPC contractors, engineering companies, equipment manufacturers and industrial operators, producing steel structures to approved drawings, material specifications and project-specific quality requirements.

Our scope ranges from individual fabricated components and equipment frames to larger structural assemblies and coordinated steelwork packages.

PETROCHEMICAL STEELWORK WE MANUFACTURE

Pipe Racks

Levstal manufactures single-level and multi-level steel pipe racks for process and utility pipelines.

The fabrication scope can include columns, beams, bracing, connection plates, pipe support frames and prefabricated structural sections manufactured for efficient transport and site assembly.

Pipe Bridges

Fabricated steel bridge structures for routing process pipelines, utility lines and cables between production areas, buildings and other parts of petrochemical and industrial facilities.

Pipe bridges are manufactured according to approved structural drawings, specified loads, connection details and installation requirements.

Process Equipment Support Structures

Steel frames, support towers, bases and structural assemblies for process equipment.

Structures are manufactured around specified equipment dimensions, static and dynamic loads, mounting points, access requirements and installation interfaces.

Equipment Skids and Base Frames

Custom welded skids, equipment bases and mounting frames for pumps, compressors, dosing units, filtration equipment and other process systems.

Levstal manufactures the structural and mechanical package according to customer drawings and equipment supplier requirements, including defined loads, connections, lifting points and transport limitations.

Modular Process Structures

Prefabricated steel frames and structural modules prepared for the integration of process equipment, piping, electrical systems and instrumentation.

Modules can be manufactured as complete structures or transportable sections, depending on project dimensions, logistics and site assembly requirements.

Platforms, Walkways and Access Systems

Maintenance platforms, walkways, stairs, ladders, handrails and grating assemblies for access to process equipment, valves, instruments and inspection areas.

Access steelwork can be supplied as standalone assemblies or integrated into larger equipment support and process structures.

Cable and Utility Support Structures

Fabricated steel supports and frames for cable trays, utility lines, ventilation systems and other technical services within petrochemical and industrial facilities.

Furnace Support Structures

Structural steel frames, platforms, access systems and custom welded components for industrial furnaces and thermal processing equipment.

Fabrication requirements are defined according to equipment interfaces, structural loads, operating conditions and project documentation.

Duct and Gas Channel Components

Custom fabricated duct sections, gas channels, transitions, casings and supporting steel structures manufactured according to customer drawings and dimensional requirements.

Chimney and Stack Components

Fabricated steel sections, support structures, maintenance platforms and access components for industrial chimneys and stack systems.

Equipment Enclosures and Protective Structures

Steel housings, equipment guards, weather-protection structures and external enclosures for process and auxiliary equipment.

Industrial Buildings and Structural Steelwork

Structural steel fabrication for process buildings, equipment halls, warehouses and auxiliary facilities.

The scope can include columns, beams, trusses, bracing, secondary steelwork and other load-bearing components supplied individually or as coordinated fabrication packages.

Replacement Steelwork and Custom Components

Levstal manufactures replacement steel structures and custom welded components for plant upgrades, maintenance shutdowns and modernisation projects.

Existing components can be reproduced from approved drawings, site measurements or customer-provided technical documentation.

STEEL FABRICATION FOR NEW PLANTS AND MODERNISATION PROJECTS

Levstal supports both new petrochemical construction and the upgrade of existing industrial facilities.

Depending on the project, we can manufacture individual components, repeatable assemblies or coordinated steelwork packages prepared for transport and installation.

Before production, our team reviews the available technical documentation and key fabrication requirements, including:

• Manufacturing drawings and 3D models
• Bills of materials and required quantities
• Steel grades and material specifications
• Equipment and piping interfaces
• Static and dynamic loads
• Welding requirements
• NDT and inspection requirements
• Dimensional and installation tolerances
• Surface preparation and coating systems
• Fire-protection coating requirements
• Trial assembly requirements
• Packing and transport restrictions
• Manufacturing and quality documentation

This technical review helps identify critical fabrication, inspection and interface requirements before the project enters production.

PETROCHEMICAL FABRICATION EXPERIENCE

Reformer Furnace Structure — Germany

Levstal manufactured a 25-tonne, 15-metre-long circular reformer furnace structure for a customer in Germany.

The equipment was intended for operation at temperatures of approximately 1,000°C. The manufacturing scope included large welded components, refractory lining and supporting structures required for transport and subsequent integration.

The project required close dimensional control and coordination between fabrication, lining, handling and transport requirements.

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QUALITY CONTROL AND PROJECT DOCUMENTATION

Petrochemical steel fabrication often requires controlled welding procedures, material traceability, dimensional accuracy and documented inspection throughout production.

Levstal manufactures according to approved project documentation and the agreed inspection and quality requirements.

Depending on the project, the manufacturing documentation package can include:

• Material certificates
• Welding documentation
• Inspection and test plans
• Dimensional inspection reports
• NDT reports
• Surface treatment and coating records
• Final manufacturing dossier

Inspection scope and documentation requirements are agreed before production and incorporated into the project quality plan.

BUILT FOR INDUSTRIAL OPERATING CONDITIONS

Steel structures used in petrochemical facilities may be exposed to high temperatures, vibration, mechanical loads, aggressive environments and demanding maintenance conditions.

Material requirements, welding procedures, inspection methods, corrosion protection and dimensional controls are therefore defined around the intended application and project specifications.

For large or complex assemblies, trial fitting can be carried out where required to verify geometry, connections and assembly sequence before delivery.

SEND US YOUR PETROCHEMICAL PROJECT

Looking for a steel fabrication partner for a petrochemical plant, expansion or modernisation project?

Send us your drawings, specifications, bill of materials, required quantities and delivery schedule. Our team will review the technical package, clarify the manufacturing scope and prepare a project-specific quotation.