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Formed 316L stainless steel equipment housing staged on a pallet in the fabrication bay

Catastrophic weld failure, solved by redesign

A food & beverage OEM's stainless weld joints were failing in the field. Root cause: joint geometry the previous shop never adjusted for service conditions.

  • 316L Stainless Steel

The Challenge

Food & beverage OEM was seeing stainless weld joints fail in the field within months. Previous fabricator had not adjusted joint geometry for the service environment.

Our Approach

Full-penetration GTAW welding, CNC forming to 0.030 inch flatness tolerance, pickling and passivation per ASTM A380.

The Result

Zero NCRs, passed radiographic inspection on first submission. Customer returned with repeat orders.

Client Requirements

A leading food and beverage equipment OEM needed a run of custom mixer housings fabricated from 316L stainless steel. The housings had to meet 3-A sanitary design requirements for crevice-free welds, hold tight flatness tolerances on the mating flange, and ship with full material traceability from mill certs through final inspection.

Northern’s Approach

We pulled in GTAW welders qualified to ASME Section IX on sanitary procedures and routed the work through our dedicated stainless-only production space to prevent carbon contamination. Forming was staged on our press brake with custom tooling to hold the 0.030-inch flatness tolerance across the full flange face. After welding, every housing was pickled and passivated per ASTM A380 in our 55-foot pickling booth, then re-passivated before final inspection.

Outcome

The first submission passed radiographic inspection with zero rejects. The customer returned with repeat orders within the quarter and has specified Northern as the sole fabricator for the housing family on subsequent equipment lines.

From the floor

More documented builds

The requirement, the approach, and the measured result on other Northern projects.

The Sunset Spectacular, a 67-foot stainless steel media tower by Orange Barrel Media, on the Sunset Strip at twilight

All 72 Ohio-built components assembled in West Hollywood with zero fit-up issues. The project won the 2021 Tekla North America BIM Award for Best Small Project and the 2017 AIA|LA Next LA Honor Award.

Fabricating the Sunset Spectacular

A 67-foot, 100-ton stainless steel monocoque with 72 unique multi-ton panels, sharp corners that ruled out press brake forming, and no two faces parallel. As designed, the structure was considered unbuildable.

Stainless steel exhaust ductwork at power generation facility

Sections dropped into position on site without field rework. Factory dry-fit eliminated forced alignment and saved significant installation labor.

When the original spec was unbuildable

Power generation facility needed large-diameter stainless exhaust ductwork to mate to existing in-plant flanges during a scheduled outage, with zero tolerance for forced alignment on site.

304 Stainless Steel
100-foot 304L stainless steel trough for wastewater treatment

Delivered straight within 1/8 inch over 100 feet, tighter than spec. Installed without field rework.

A 100-foot stainless trough, straight within 1/8"

Regional wastewater authority needed a 100-foot 304L stainless trough to replace a failed unit during a planned outage. Straightness was specified within 1/8 inch over the full 100-foot length. The previous fabricator couldn't hold tolerance over the span.

304L Stainless Steel

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