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Caissons and Monopiles

Caissons and Monopiles

Greens Bayou Pipe Mill manufactures structural steel pipe in various sizes, wall thicknesses, and finishes for marine caisson and monopile applications. Products are fabricated per API 2B, API RP2A & AWS D1.1 requirements, unless otherwise stated, from flat steel progressively rolled and welded into the finished size and shape.

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Marine caisson and monopiles
What are caissons and monopiles?

Caissons and monopiles are watertight structures that support work on marine application foundations. They’re prefabricated hollow boxes or cylinders sunk into the ground until reaching the desired depth. Concrete is poured, forming a foundation.

These devices are used to construct bridges, dams, offshore platforms, and other structures that require solid foundations beneath rivers, lakes, or oceans. They hold back water when founding pilings or piering a foundation, especially when it’s necessary to drill into subsea material or below the waterline. 

Our capabilities

Greens Bayou Pipe Mill is a leading caisson and monopile pipe foundation manufacturer. Our area of expertise is the immediate turnaround of API 2B compliant carbon steel pipe for demanding industrial use.

With five rolling machines capable of handling plates up to 10 inches thick, we’ve unmatched structural steel pipe production capacity. Actual forming capacities depend upon the product grade, diameter, wall thickness, and length.

High loads and pressures require quality fabrication

Our monopile and caisson pipe fabrication capabilities are unmatched. Longitudinal seams are welded using efficient and precise automated submerged-arc welding, or SAW, processes. 

The sides of plates fed through the rollers curl toward each other, forming a cylinder. Filler material is passed along the edges, on the inside and outside diameters, joining them together.

After assembly, the circumferential weld is performed. We have an extensive catalog of welding procedures to cover many types of material and designs.

SAW is a pressure-free process. A blanket of granular fusible material shields the arc. Benefits of this welding technique are: 

  • High Weld Quality 
  • High Deposition Rate
  • Deep Weld Penetration 
  • Smooth Finished Weld
  • No Spatter

Finished pipe tailored to the client

Acquiring structural steel pipe in the desired condition may require additional processing, which calls for transiting in-process material between service providers. With Greens Bayou Pipe Mill, that’s not the case. We offer an array of value-added services under one roof, streamlining your supply chain. 

  • Assembly
  • Non-Destructive Testing, or NDT
  • Post-Weld Heat Treatment 
  • Coating 
  • Load Out 

Proving out your caissons and monopiles

An independent inspection agency checks welds for nonconformities. Any relevant indications found are documented by type and location before the pipe returns to the welding area for repair. 

Subsurface and surface NDT methods can be performed per any ASNT recommended practice or AWS, API, ASTM, and ASME standard. Customer-supplied NDT procedures are also welcome. Typical types of inspections performed include: 

  • Radiographic Testing, or RT
  • Ultrasonic Testing, or UT
  • Magnetic Particle Inspection, or MPI
  • Liquid Penetrant Inspection, or LPI 

Custom marine foundation pipe delivery

As a top caisson and monopile pipe foundation manufacturer, Greens Bayou Pipe Mill tailors product delivery to customer needs. Our team works with you to come up with an optimal shipping solution, whether it’s by: 

  • Truck
  • Rail
  • Vessel

We’re located at the convergence of Greens Bayou and the Houston Ship Channel, which connects directly to the Gulf of Mexico. Our crews can load out up to 500 tons of structural steel pipe using a barge-mounted crane.

Quality is never compromised

Every job is approached with a quality-first mindset. As an structural steel pipe supplier, all processes follow a strict quality management system. 

Precision testing and inspection equipment ensure every product surpasses applicable industry standards or customer specifications. All orders are audited for accuracy before shipment. 

Contact us to learn more about our monopile and caisson pipe fabrication services. 

Ready to get started? 713-450-8959