Project Overview
Openex Metal Fabrication recently completed a massive, time-sensitive contract to deliver a diverse series of Atmospheric Storage Tanks and Equipment Components for a key industrial client. Because of our massive facility space and 100% in-house capabilities, we executed a complete "One-Stop Turnkey Delivery"—handling everything from raw material integration to complex manufacturing and final logistics.
Across two consecutive contract phases, our engineering and production teams successfully delivered 180 complete units totaling over 400 metric tons of high-quality industrial steel equipment.
The Challenge
The production demands for this order were extreme due to the variety and scale of the tanks required. The project presented four core challenges:
- High Complexity & Diversity: The contract required dozens of different tank shapes, component configurations, and thicknesses.
- Strict Interlinked Workflows: Almost every piece required sequential cross-department operations (rolling, welding, then post-weld machining).
- High Output Volume: Processing, handling, and staging over 400 tons of material required immense floor space and lifting capacities.
- Aggressive Deadlines: The customer needed rapid deployment to prevent delays at their project installation site.
Our Fabrication Solution
To meet the aggressive schedule, Openex launched a dedicated Project Task Force before material even arrived on the shop floor. We established highly detailed work instructions and deployed a continuous cellular "assembly line" batch production mode across our factory.
The Complete Turnkey Process Run:
1. Material Supply & Profiling: Precision CNC cutting and specialized edge beveling for optimal weld penetration.
2. Forming & Bending: Heavy plate rolling and high-capacity press braking of tank shells and geometries.
3. Initial Assembly & Welding: Code-certified heavy welding with automated rotation.
4. Structural Reshaping & Straightening: Managing intense thermal weld-distortion.
5. Post-Weld CNC Machining: Advanced capability ensuring 100% flatness and tolerance on massive finished tank flanges.
6. Quality Assurance: NDT weld seam inspections, finishing, final packaging, and direct site-delivery.
Through seamless project management—supported by instant-response digital team channels and daily stand-up coordination—every single tank and component passed stringent quality controls and arrived at the client’s facility strictly on schedule.
