Rack and pinion production for general overhaul of a jack-up rig: High-strength solutions for maritime challenges

Quality management

A service provider for the maritime, offshore and oil industry from the Middle East has commissioned UnionStahl to manufacture gear racks for the general overhaul of one of its jack-up rigs. This project impressively demonstrates how high-strength materials, precise processing and comprehensive quality management enable sustainable solutions in the offshore industry.

Initial situation: customer requirements and first steps

The established player in the maritime industry needed a customized solution for the general overhaul of one of its jack-up rigs. Thanks to our network and expertise, we were able to respond to the customer’s requirements at short notice.

UnionStahl impressed with its many years of experience and the technical expertise required to manufacture these special racks. The order included single-sided racks that are welded onto the tubular legs of the jack-up rig. This design is typical for this type of installation, but requires the highest precision and materials with exceptional load-bearing capacity.

The solution: high-strength materials and precise manufacturing

Sheets made of S690QL1 with a Z35 material test (tensile test in the thickness direction) were used for production. This material was specifically chosen as it is optimized for extreme loads in the offshore industry and meets the high safety requirements.

Technical details:

• Material: S690QL1, 130 mm thick, with Z35 test
• Cutting tolerances: Tight specifications that required maximum precision during processing
• Flatness tolerances: Strict requirements to ensure problem-free installation and maximum functionality

Special challenges in production:

1. Material availability: S690QL1 with Z35 testing in this thickness is rarely available on the market.
2. Cutting experience: Tight tolerances and high demands on flatness required experienced specialists and specialized machines.
3. Comprehensive quality management: Every phase of production was monitored, tolerances were measured and documented to ensure complete traceability.

Advantages for the customer: Safety and reliability

The use of S690QL1 with Z35 testing offers a number of advantages for the customer:

• Reliability: The racks meet the highest requirements for stability and load-bearing capacity.
• Precision: Precise manufacturing and comprehensive quality controls guarantee problem-free installation.
• Expertise: UnionStahl was able to impress with its quick action and technical expertise, which led to a smooth implementation of the project.

Customer quote: “UnionStahl impressed us with their precise production and high material quality. The collaboration was professional and efficient.”

Conclusion: Expert knowledge and flexibility as success factors

This project impressively demonstrates how important the combination of technical expertise, flexible production and high-quality materials is for the maritime industry. Racks made of high-strength steel such as S690QL1 with Z35 testing are essential to ensure the safety and durability of jack-up rigs.

Outlook

UnionStahl is ideally prepared to realize similar projects in the offshore sector or in related industries such as the wind power or shipbuilding industry. With our broad network and production capacities, we can also implement demanding repair and production orders at short notice.

Added value for other sectors

Although these racks were manufactured specifically for jack-up rigs, this project shows how versatile high-strength materials such as S690QL1 are. They are also ideal for use in the construction industry or in wind turbines thanks to their resilience and precision.