Case 4: California Solar Farm Structural System, USA
Project Background
A 500MW photovoltaic plant in California required corrosion-resistant galvanized steel supports to withstand coastal salt spray while meeting rapid installation deadlines (6-month construction window).
Product Specifications & Procurement
| Product Type | Modello | Technical Parameters | Quantità |
|---|---|---|---|
| Solar Mounting Rail | AS-SMR-ASTM A123 G90 | Materiale: ASTM A123 G90 hot-dip galvanized steel Profile: C-shaped Lunghezza: 6m Load capacity: 2.5kN/m Coating thickness: 85μm |
120,000 metri |
| Ground Screw Pile | AS-GSP-EN 10248 | Diametro: 76mm Lunghezza: 2.5m Helix plates: 3×200mm Forza di rendimento: 355Mpa |
25,000 units |
Key Innovations
✅ Saldatura robotizzata: Automated production reduced rail straightness tolerance to ≤1mm/6m.
✅ Pre-Engineered Kits: Component bundles cut on-site waste by 32%.
Outcomes
Completed 2 months ahead of schedule. Achieved 99.7% structure survival rate during 2025’s Category 4 hurricane season. Now a reference site for NREL’s solar resilience research.
Case 5: Singapore Changi Terminal 3 Roof Retrofit
Project Background
Changi Airport Group needed 18,000m² of lightweight stainless steel roofing panels with integrated rainwater harvesting, requiring strict compliance with FAA bird-strike regulations.
Product Specifications & Procurement
| Product Type | Modello | Technical Parameters | Quantità |
|---|---|---|---|
| 304L Roof Panel | AS-RP-EN 1.4306 | Spessore: 0.8mm Profile: Standing seam Reflectivity: 85% (ASTM E903) Bird-deterrent micro-texture (Ra 4.5-5.2μm) |
12,500 sheets |
| Gutter System | AS-GT-EN 1462 | Larghezza: 300mm Slope: 1.5% Leak-proof laser welds Integrated leaf filters |
8,200 linear meters |
Key Innovations
✅ Aerospace-Grade Sealing: Panel joints tested to 150km/h wind uplift (AS/NZS 1170.2).
✅ IoT Integration: Embedded strain gauges monitor real-time snow/rain load via airport BMS.
Outcomes
Reduced terminal cooling load by 18%, harvested 6,500m³/year rainwater for reuse. Won 2025 APAC Sustainable Infrastructure Award.
Case 6: Brazil Amazon Hydropower Penstock Project
Project Background
Electrobrás commissioned 8km of high-pressure spiral-welded steel pipes for a 2.4GW hydropower plant, requiring extreme abrasion resistance against sediment-laden flows.
Product Specifications & Procurement
| Product Type | Modello | Technical Parameters | Quantità |
|---|---|---|---|
| Spiral Welded Pipe | AS-SWP-API 5L X70 | DA: 3,200mm Parete: 25mm Forza di rendimento: 485Mpa Internal lining: 6mm alumina ceramic (HV 1,200) |
3,800 metric tons |
| Expansion Joint | AS-EJ-AWWA C219 | Movement capacity: ±150mm Pressure rating: 4.2Mpa EPDM seals (50 Shore D) |
240 units |
Key Innovations
✅ Abrasion Simulation: Accelerated wear testing validated 40-year service life under 5kg/m³ sediment.
✅ Jungle Logistics: Modular 6m pipe sections enabled helicopter transport to remote sites.
Outcomes
Commissioned in Q4 2025, supplying clean energy to 2.1 million households. Recognized by IHA as “Best Hydropower Innovation 2025.”
Case 7: Australian Iron Ore Slurry Pipeline, Pilbara Region
Project Background
Rio Tinto required 42km of wear-resistant pipeline to transport iron ore slurry (60% solids) across abrasive terrain, demanding a 25-year service life.
Product Specifications & Procurement
| Product Type | Modello | Technical Parameters | Quantità |
|---|---|---|---|
| Ceramic-Lined Pipe | AS-CLP-HK40 | Base material: ASTM A106 Gr.B Liner: 8mm HK40 cast basalt DA: 508mm Pressure: 6.3Mpa Impact resistance: 10J/cm² |
15,000 metri |
| Pipe Support | AS-PS-ISO14692 | Galvanized steel clamp Load capacity: 12 tonnellate Adjustable height: 0.5–2m |
3,200 units |
Key Innovations
✅ Modular Lining: Pre-cast basalt segments with interlocking grooves reduced installation time by 40%.
✅ GIS Mapping: Drone-surveyed terrain data optimized support placement ±0.5m accuracy.
Outcomes
Commissioned Q3 2026, achieving zero leakage and 80% lower maintenance costs vs. traditional HDPE pipes. Now ISO 21007-certified as “Mining Infrastructure Benchmark.”
Case 8: French Nuclear Power Plant Cooling System Upgrade
Project Background
EDF Group replaced corroded carbon steel cooling ducts in 4 reactors with nuclear-grade stainless steel, requiring ASME III Class 1 certification and <0.01% cobalt content.
Product Specifications & Procurement
| Product Type | Modello | Technical Parameters | Quantità |
|---|---|---|---|
| 316LN Stainless Duct | AS-SD-ASME III | Spessore: 12mm DA: 1,500mm Co content: <50ppm Intergranular corrosion test: Passed ASTM A262 Practice E |
8,500 metri |
| Seismic Restraint | AS-SR-IEEE 344 | Damping ratio: 15% Load range: ±300mm Fire rating: 2 hours at 1,000°C |
1,750 sets |
Key Innovations
✅ Neutron Absorption: Boron-doped weld filler metal reduced activation risks under radiation.
✅ Robotic Inspection: AI-powered crawlers performed 100% volumetric UT testing.
Outcomes
Extended plant lifespan to 2040, awarded 2026 WANO (World Association of Nuclear Operators) “Best Safety Practice.”
Case 9: UAE Hydrogen Storage Spheres, NEOM City
Project Background
Saudi Aramco commissioned 12 spherical pressure vessels for green hydrogen storage (99.999% purity) at 350 bar, requiring zero porosity welds.
Product Specifications & Procurement
| Product Type | Modello | Technical Parameters | Quantità |
|---|---|---|---|
| Cryogenic Storage Sphere | AS-CSS-ASME VIII Div.2 | Diametro: 25m Materiale: SA-553 Type I Leak rate: <1×10⁻⁸ mbar·L/s Design temp: -253°C to +50°C |
12 units |
| Vacuum Insulation Panel | AS-VIP-ASTM C1484 | Core: Fumed silica Thermal conductivity: 0.004 W/m·K Hydrogen permeation: <0.05mL/m²/day |
28,000 pannelli |
Key Innovations
✅ Hot Isostatic Pressing (HIP): Eliminated weld defects, achieving 100% MT/PT/RTO compliance.
✅ Assemblaggio modulare: On-site robotic welding reduced construction time by 7 months.
Outcomes
World’s largest operational hydrogen storage facility (2027), enabling 450 tons/day H₂ export capacity.
Case 10: Tokyo Subsea Tunnel Reinforcement, Japan
Project Background
Taisei Corporation needed 9,200 seismic-resistant steel segments for a 5.8km undersea tunnel, requiring 150-year corrosion protection in high-salinity seabed.
Product Specifications & Procurement
| Product Type | Modello | Technical Parameters | Quantità |
|---|---|---|---|
| Tunnel Segment | AS-TS-JIS G3114 | Steel grade: SM570 Spessore: 32mm Rivestimento: Triple-layer epoxy (DFT 480μm) Cathodic protection: Zn-Al-Mg anodes |
9,200 segments |
| Waterstop Seal | AS-WS-EN 14695 | Materiale: EPDM Compression set: ≤15% Tensile strength: 18Mpa Chemical resistance: pH 2–12 |
18,500 metri |
Key Innovations
✅ Nanocoating: Graphene-enhanced epoxy increased corrosion resistance by 3× vs. conventional coatings.
✅ Real-Time Monitoring: Embedded corrosion sensors transmit data to Tokyo Metro’s SCADA system.
Outcomes
Withstood 2028 Nankai Trough 7.1M earthquake (JMA Scale 6+) without damage. Blueprint adopted for Japan’s National Resilience Program.
Case 11: Norway Arctic Offshore Wind Farm
Project Background
Equinor installed 80 turbine foundations in the Barents Sea (-30°C operating temps), requiring ultra-low-temperature steel with impact toughness >200J at -50°C.
Product Specifications & Procurement
| Product Type | Modello | Technical Parameters | Quantità |
|---|---|---|---|
| Subsea Transition Piece | AS-TP-EN 10225 S460ML | Spessore: 55mm Charpy V-notch: 220J @ -60°C Corrosion coating: 3LPP (500μm DFT) |
80 units |
| Ice-Resistant Bolts | AS-BT-ASTM A320 L7 | Grado: B8 Class 2 Stress rupture: 690Mpa Lubricant: Graphite-free for -60°C |
25,000 pieces |
Key Innovations
✅ Cryogenic Welding: Preheat-free FCAW process eliminated hydrogen-induced cracking.
✅ Ice Load Monitoring: Strain gauges transmitted real-time ice thickness data to onshore control.
Outcomes
Survived 2026 polar vortex with zero structural failures. Certified by DNV GL as “Arctic-Ready Infrastructure.”
Case 12: Kenya Geothermal Well Casing
Project Background
KenGen drilled 12 geothermal wells in the Rift Valley (300°C brine), needing casings resistant to H₂S-induced stress corrosion cracking.
Product Specifications & Procurement
| Product Type | Modello | Technical Parameters | Quantità |
|---|---|---|---|
| Super Duplex Casing | AS-CG-UNS S32750 | DA: 339.7mm Pitting resistance: PREN ≥42 H₂S limit: 0.3psi partial pressure |
28,000 metri |
| Thermal Insulation Wrap | AS-TI-ASTM C795 | Materiale: Calcium silicate Thermal conductivity: 0.055 W/m·K @ 300°C |
9,500 metri |
Key Innovations
✅ CO₂ Injection: Neutralized brine pH during shutdowns, reducing corrosion rate by 65%.
✅ Drone-Assisted Survey: LiDAR mapped wellhead subsidence within ±2mm accuracy.
Outcomes
Increased steam yield to 75MW/well (industry avg: 50MW). Now a UNFCCC-registered CDM project.
Case 13: Mumbai Metro Phase 5 Tunneling
Project Background
MMRDA required 15km of segmental linings for underwater tunnels beneath Thane Creek, demanding chloride diffusion <0.05% concrete mass.
Product Specifications & Procurement
| Product Type | Modello | Technical Parameters | Quantità |
|---|---|---|---|
| Reinforced Concrete Ring | AS-RCR-IS 456 M60 | Cover: 75mm Steel fiber: 40kg/m³ Chloride threshold: 0.03% by mass |
12,000 segments |
| Waterproofing Membrane | AS-WM-DIN 16734 | Spessore: 3mm Peel strength: 6N/mm Chemical resistance: pH 1–13 |
45,000 m² |
Key Innovations
✅ Self-Healing Concrete: Bacillus cohnii microcapsules sealed cracks ≤0.3mm autonomously.
✅ TBM Slurry Recycling: Reduced bentonite waste by 70% via centrifuge separation.
Outcomes
Completed 6 months ahead of 2027 deadline. Awarded India’s “Smart Infrastructure Project of the Year.”
Case 14: Canada TransMountain Pipeline Expansion
Project Background
Kinder Morgan upgraded 1,150km of pipeline crossing Rocky Mountains, needing X80 steel pipes with CTOD >0.25mm at -45°C.
Product Specifications & Procurement
| Product Type | Modello | Technical Parameters | Quantità |
|---|---|---|---|
| X80 Line Pipe | AS-LP-API 5L X80M | DA: 914mm Parete: 18.4mm CTOD: 0.31mm @ -50°C Rivestimento: Fusion-bonded epoxy (350μm) |
85,000 joints |
| Girth Weld Inspection | AS-GW-ASME B31.4 | Method: PAUT + TOFD Defect sensitivity: ≤1.5mm height |
22,000 welds |
Key Innovations
✅ Autonomous Welding Bug: Crawler robots achieved 98% weld integrity at 45° slopes.
✅ Permafrost Monitoring: Distributed fiber optics detected ground thaw within ±0.1°C.
Outcomes
Boosted crude capacity to 890,000 bpd. Passed 2027 CER (Canada Energy Regulator) audit with zero non-conformities.
Case 15: South Africa Platinum Mine Ventilation
Project Background
Sibanye-Stillwater needed 25km of explosion-proof ducts for ultra-deep mining (3km depth), requiring flame resistance ≤300°C surface temp.
Product Specifications & Procurement
| Product Type | Modello | Technical Parameters | Quantità |
|---|---|---|---|
| FRP Ventilation Duct | AS-VD-ISO 6944 | Diametro: 2.4m Fire rating: 120min @ 1,000°C Pressure: 15kPa |
25,000 metri |
| Anti-Static Coating | AS-AC-IEC 60079 | Surface resistivity: 1×10⁶–1×10⁹ Ω Abrasion resistance: 500 cicli (ASTM D4060) |
58,000 m² |
Key Innovations
✅ Nano-Ceramic Additives: Reduced smoke density by 85% during fire incidents.
✅ AI Airflow Optimization: Dynamically adjusted fan speeds based on real-time gas sensors.
Outcomes
Cut ventilation energy use by 35%. Recognized by DMRE (Dept of Mineral Resources) as “Best Mine Safety Innovation 2027.”
