Case Study: High-Precision Steel Structure Fabrication for Power Plant Boiler Project

Client: Huadian Engineering Co., Ltd. (China)

Industry: Power Generation  Petrochemical

Project: Boiler Steel Structure Flue Duct System

Location: Philippines

Completion: March 2026

Scope: 1,200+ tons of heavy steel structure, full fabrication, NDT inspection, anti-corrosion coating, and export packaging

1. Client Challenge .The client required a high-strength, corrosion-resistant steel structure for a coal-fired power plant boiler system in the Philippines, with strict requirements:

1.1 Tight delivery:

90-day fabrication and delivery window

1.2High precision:

±2mm tolerance for main beam assembly

1.3 Stringent quality:

Full compliance with AWS D1.1, ISO 9001, and project-specific NDT standards (UT, MT, RT)

1.4 Logistics:

Sea-worthy packaging for long-distance ocean transport 

1.5Complex geometry:

Non-standard box columns, H-beams, and truss connections  

2. Why Xinghua Steel Structure Was Selected

2.1Full production capacity:

50,000 tons annual output; 40,000 ㎡ workshop with 100-ton crane capacity

2.2Advanced equipment:

Automated H-beam, box column, and tube truss production lines; in-house NDT lab

2.3Proven track record:

Successful delivery of similar power plant projects in China and Southeast Asia

 2.4Certifications:

Steel Structure Manufacturing Grade 1, ISO 9001/14001/45001 certified 

2.5End-to-end service: 

Design optimization, fabrication, inspection, coating, and export documentation 

 3. Our Solution  Execution

3.1 Pre-Project Engineering 

 Conducted 3D BIM modeling (Tekla) to detect clashes and optimize connections

Developed custom welding procedures and quality control plans

Shared detailed shop drawings and inspection protocols for client approval  

3.2 Fabrication Process

 Material sourcing: High-grade Q355B / Q355ND steel plates from reputable mills

 Cutting  assembly: CNC plasma cutting, automated assembly lines

Welding: Certified welders following AWS D1.1 standards 

NDT inspection: 100% UT/MT for critical welds; RT for key joints 

Surface treatment: Sandblasting (Sa 2.5) + two-layer heavy-duty anti-corrosion coating 

 Packaging: Wooden cradles, steel banding, and moisture barriers for ocean transport

 3.3 Quality Assurance

• In-process inspection at every production stage

• Final dimensional verification and full NDT report

• Third-party inspection (SGS / BV) witness as required

• Complete material traceability and quality documentation package  

4. Project Results  Benefits

• On-time delivery: Completed fabrication in 82 days (8 days ahead of schedule)

• Zero defects: 100% pass rate on all NDT and dimensional inspections

• Cost efficiency: Optimized design reduced material waste by 8% vs. initial plan

• Logistics success: Safe arrival at Philippines port with no damage

• Client feedback: “Xinghua’s technical expertise, strict quality control, and reliable delivery made this complex power plant steel structure project a success. We look forward to future cooperation.”— Project Director, Huadian Engineering  

5. Key Takeaways

• BIM integration significantly reduces rework and speeds up fabrication

• In-house NDT capability ensures quality and shortens inspection cycles

• End-to-end project management minimizes client coordination effort

• International standard compliance builds trust for global projects  

6. About Shandong Xinghua Steel Structure Co., Ltd. Established in 2022, Xinghua Steel Structure is a leading steel structure manufacturer based in Liangshan, Jining, Shandong, China. We specialize in:

• Power plant, petrochemical, bridge, and industrial steel structures

• Heavy steel fabrication, tube trusses, and complex steel components

• Design, fabrication, coating, and export services

• ISO 9001 / 14001 / 45001 certified; Steel Structure Manufacturing Grade 1