When it comes to the marine industry, precision and safety are crucial. That’s why it’s essential to partner with a reputable marine fabricator experienced in designing and fabricating shipshape metal work.
Steel fabrication for marine environments is a demanding niche that demands expert knowledge and skill. This is where marine fabricators like Carver Engineering, come in.
From bespoke subsea structures to pipelines and riser systems, Carver is certified to produce high standard marine fabrication designed with the correct steel grades to withstand challenging maritime environments.
In this article, we’ll explore the role of marine fabricators, the kinds of steel fabrications required in the marine industry, and any key considerations we need to keep in mind when designing and fabricating marine structures. Plus, you’ll see some of our marine fabrication work in action…
What does a marine fabricator do?
Marine fabricators essentially create and maintain robust marine and subsea structures, equipment and components, including pipework, railings and footbridges, manifolds, mudmats, clamps and risers.
Marine fabricators’ expertise goes beyond standard metalworkers. Unlike land-based constructs, marine and subsea structures can be exposed to saltwater, sun exposure and even the pressure of the ocean floor.
This means that marine fabricators require specialised skills and expertise in creating components that can withstand these unique conditions. This includes understanding the importance of corrosion resistance, structural integrity and weight optimisation.
Core responsibilities of marine fabricators
Marine fabricators design, engineer, and construct a wide range of steel components for offshore and subsea structures. Here are some of the projects a marine fabrication company can support with:
- Hull components: Reinforcements, repairs, and custom additions.
- Deck structures: Including walkways, ladders, and safety railings.
- Port equipment: Custom hoppers, cranes, and material handling systems.
- Offshore infrastructure: Oil rig supports, wind turbine platforms, and underwater structures.
- Specialised fabrications: Such as anti-corrosion linings, heavy-duty storage tanks, and bespoke machinery housings.
Marine fabrication requires a bespoke approach, which is why the team at Carver provides a complete in-house detailed design service. Whatever the unique demands of your project, we can support – whether it’s engineering a structure to withstand immense saltwater corrosion to a tight operational deadline or refurbishing and reinforcing critical components for an existing structure.
Steel fabrications in the marine industry
Steel is the backbone of marine construction, offering the strength and resilience needed to handle challenging maritime conditions. But not all steel is created equal. Marine-grade steel fabrication often involves specialised alloys, finishes, and grades designed to withstand both physical and chemical wear.
Key types of marine steel fabrications
Structural reinforcements
Steel reinforcements ensure vessels and facilities can endure immense stresses, from wave impacts to heavy cargo loads.
Bespoke machinery components
Custom-designed hoppers, cranes, and conveyor systems require precise engineering to function in unique operational settings.
Anti-corrosion solutions
Coatings and specialised grades of steel are crucial for resisting saltwater corrosion and weathering.
Heavy-duty linings
High-impact environments, like those handling abrasive materials, rely on wear-resistant steel linings.
Safety systems
Railings, barriers, and walkways must be designed to strict standards, ensuring safety in unpredictable environments.
5 key considerations for marine steel fabrication
Fabricating for the marine industry requires meticulous planning, precise material selection, and an in-depth understanding of the operational environment. Here’s everything our marine fabricator will consider at the outset of your project.
1. Material selection
Choosing the right grade of steel is essential. For marine applications, steel must resist both corrosion and wear. Common marine-grade steels include:
- Stainless steel: Favoured for corrosion resistance.
- AR (Abrasion-Resistant) steel: Designed for high-impact environments.
- Corten steel: A weathering steel that forms a rust-like patina for natural corrosion resistance.
2. Corrosion resistance
Saltwater is notoriously corrosive, so our marine fabricator team uses protective coatings, galvanisation, or corrosion-resistant alloys to extend the lifespan of marine structures.
3. Structural integrity
Marine structures, particularly those at subsea level, need to endure immense loads, vibrations and stresses. We ensure that every weld, bolt, and joint is executed with precision to ensure safety and performance.
4. Compliance with regulations
The marine industry operates under strict regulatory oversight. Marine fabricators must adhere to quality, safety, environmental, and operational standards, such as ISO certifications and maritime safety codes.
At Carver Engineering, we’ve held ISO 9001 accreditation since 1994, which is testament to the outstanding work we do. On top of this, our welding procedures are in accordance with BS EN ISO 3834-2:2005 and all products are CE marked as compliant with European regulations.
5. Adaptability for harsh environments
Marine equipment often faces constant exposure to UV, salt, and moisture. Fabricators must consider these factors in both design and material choices.
Marine fabricator case study: The Tilbury Hopper
We’ve been supporting the marine and subsea sector with high quality steel fabrication services for more than three decades. A recent project saw us take on the fabrication of a hopper at the Port of Tilbury commissioned by British engineers, the Spencer Group, designed to increase the port’s offloading capacity.
Project background
The Tilbury hopper’s primary role was to break up and handle abrasive materials, and would also be exposed to the coastal elements. As such, this project demanded both structural strength and resistance to wear.
The steel: AR450
We lined the hopper’s interior with AR450 steel, a grade specifically engineered for abrasion resistance. AR450 is particularly suited for high-impact environments where materials like rock and debris are constantly in motion – making it a perfect match for this project.
Its unique properties include:
- Exceptional hardness: With a hardness rating of 450 on the Brinell scale, it withstands heavy wear.
- Impact resistance: The steel maintains structural integrity under immense stresses.
- Prolonged lifespan: Reducing the need for frequent maintenance or replacement.
Using AR450 for the hopper ensured it could handle the rigours of its job while minimising wear and tear over time.
Challenges and solutions
Exposure to the elements
The hopper’s constant exposure to weather meant it required corrosion-resistant coatings and robust welds to prevent degradation.
Handling abrasive materials
We required a high steel grade, AR450 steel, combined with meticulous design to minimise impact points.
Bespoke design requirements
Carver worked closely with the Spencer Group to ensure the hopper met precise specifications and was seamlessly erected and installed on site.
Start your marine fabrication project with Carver
The Tilbury hopper case study highlights the importance of choosing the right steel grade, the value of bespoke design, and having the right know-how when it comes to fabricating components for marine environments.
If you’re looking for an experienced marine fabricator, Carver Engineering is ready to deliver reliability, durability and quality. Get in touch with the team for a quote on your marine fabrication project today.
