RocCLAD Features

Roc-Master is a well-known CRA cladding specialist and a manufacturer of forgings and cladding products.
Our core technology is professional welding techniques at an international advanced level.
RocCLAD technology has been maturely used for severe corrosion, abrasion and cavitations erosion applications.
RocCLAD cladding techniques build up a CRA layer on the wet parts of pipes and other piping components to protect the piping system integrity, providing low cost and long life solutions.

RocCLAD Process

RocCLAD is a metallurgical bonding technology of two kinds of different metals. It is the 100% metal fusion technique. RocCLAD makes overlay welding on most carbon, low alloy, chrome moly, stainless steel and other steels with variety of corrosion resistant alloy including Inconel®, Incoloy®, Monel®, Hastelloy®, stainless steel and hard facing materials.
Benefiting from our advanced DSP or PLC controlled welding stations and optimized producing process, we offer very low dilution of alloy deposite. Real time video monitoring and recording system ensure perfect tie in and weld path. Iron (Fe) content of the Inconel 625 cladding layer can reach less than 5% in the surface 1 mm below the top surface with minimum 3mm total layer thickness.
The CRA layer will be achieved by weld overlay, so that our customers will obtain better anticorrosion and wear resisting property at a lower cost thereby extend the service life of piping system.
RocCLAD has been widely applied on hot induction clad bends for the long-distance transport pipeline, risers for the offshore platform, piping products for the submarine special equipments, stations, X-tree well head, DD EE FF HH grade X-trees parts, well-head valves, Hydrogenation reactors and so on, while mechanical lining method has hardly used in such working conditions. 

Why RocCLAD

Cladding VS Carbon Steel and CRA Steel

	Cladding	Carbon Steel	CRA Steel
Service Life	Longer	Shorter	Longer
Safety	Anti Corrosion + High Mechanical Property	High Mechanical Property	Anti Corrosion
Weight	No Additional Corrosion Allowance Needed	Additional Corrosion Allowance Needed	Heavier, due to lower mechanical property
Purchase	Welding Wire in Stock	Easy to Purchase	Hard to Purchase and Long Delivery
Cost Impact	If you consider long term cost	Low Cost	Expensive

Roc-Master Cladding Capability

RocCLAD Production Capacity

RocCLAD owns 25 sets of DSP or PLC controlled welding machines, which include 6 sets of horizontal and 19 sets of vertical machines. The annual consumption amount of the welding wire reaches 290 tons.
Roc-Master can produce clad pipes up to 12.2M in length and minimum diameter bore of 130mm; clad flanges, clad pipe fittings, clad bends and clad valves bodies of 30mm minimum ID.
The company also can provide cladding WPS/PQRs covering nickel based alloy, stainless steel, hard alloy surfacing and butt weld WPS/PQRs, covering carbon steel, duplex/super duplex steel, stainless steel, alloy steel and many others. Of course, if required all can be witnessed by any 3rd party. 
We have 15 tons of imported 825 & 625 welding wire, and 3 tons of domestic 316 welding wire available in stock.
RocCLAD has a special Bonded Warehouse for the imported welding wire to strengthen the competitive in the overseas projects.

 

RocCLAD Applications

• Manifold, Pipeline, Bends, Bulkhead, Flanges, Valves & Blocks for Submarine Christmas Trees.
• Risers, Bends, Elbows for Offshore Platforms
• Bends, Pipe Fittings, Flanges, Insulation Couplings for Onshore Gathering , Stations, Treatment Plant, Desulfurization and Decarbonization Device X-mas Trees
• Bends, Pipe Fittings, Flanges, Valves for Gas Processing Plant and Offloading Stations
• Branch Pipes, Parts, Flanges, Weldolet for Pressure Vessel
• Pipes, Pipe Fittings, Flanges, Valves for Anti-corrosive and Anti-abrasive Applications for Coal Oil Industries
   

Clad Pipes, Hot Induction Clad Bends

• Base Material of Pipes:
  • ASTM A53 B, A106 Gr. B, API 5L B, X42, X52, X60, X65,X70; ASTM A333 GR.6, Stainless Steel
• Thickness of Base Pipes: 6mm~ 75mm;
• OD of Pipes: DN125 ~ DN600 (130mm~600mm)
• Length of Pipes: Up to 12.2m
• Process of Bending: Hot Induction Bending and Cold Bending
• Bend Radius: 3D~ 10D or on customer’s request
• Bend Angles: For Cold Bending 1°~ 180° / For Hot Induction : 1° - 100°
• Diameter of Clad Bends: 4”~ 20”
• Wall Thickness of Clad Bends: STD~75mm
   

Clad Flanges, Clad Fittings and Clad Service

• Bore: 38mm~1800mm
• Base Material of Valves: ASTM A216 WCB, WCC; A352 LCC ... ...
• Base Materials for Flange Forgings :
  • ASTM A105/A105N, ASTM A350 LF2 CL2, LF6 CL2
  • ASTM A694 F42, F52, F60, F65, F70
  • ASTM A182 F304/304L, F316/316L
  • API 45K, 60K, 75K
  • AISI 4130 (M), 4140, 4340, 8630(M)
• Base Materials for Pipe Fittings:
  • ASTM A234 Grade WPB, WPC, WP11, WP22
  • ASTM A860 WPHY52, WPHY60, WPHY65, WPHY70
  • ASTM A420 WPL6
  • ASTM A516 GR. 60/GR. 70
• Others

Materials for Weld overlay

• Stainless Steel 304 /304L 316/316L, 317L, 347, 904L , 410
• Inconel® 600 /625 Incoloy® 800 /825
• Duplex Steel S31803, 2205, S32760, 2507, 2209
• Hastelloy® C276, C22
• Monel K-500, 400
• Cu/Ni 70/30
• Other Special Alloy Steel

Roc-Master Quality Assurance
Our experienced and qualified technicians utilize NDT techniques to ensure high quality and reliability of our products during the weld overlay process. Final documents for clients will be issued, including all inspection process recordings and procedures.

• Radiographic inspection - RT

RT test is carried out by 3rd party professional RT testing company at the cost of Roc-Master.

• Dye penetration test- DPI

All components are subjected to penetrate testing prior to overlay deposition and on completed items. Remote video-probe inspection technology is utilized on inspecting internal bore diameters of pipe. We are able to examine inside length of the pipes up to 6.5 Mtr.

• Positive Material Identification – PMI

We utilize the world's best 26-channel portable online PMI device to recheck chemical composition of the base material and cladding layer. The test reports will be completely saved in the computer on PMI device and can be traced. Shanghai Research Institute of Materials and the imported specimen ensure the PMI accuracy.

• Ultrasonic Testing – UT

We utilize the world’s advanced wave and standing wave detector to do the ultrasonic testing on the integrity of the weld overlay layer and the base material to guarantee the cladding quality. Roc-Master strictly comply to the customer’s measuring standards of cladding thickness.

• Magnetic Particle Testing— MT

We utilize fluorescence or visual techniques to test the surface defect on ferromagnetism components after all production phases are completed.

• Visual Test—VT

Using remote video camera techniques and through the outlay screen, we can examine the cladding appearance and record the VT process media. VT process media will be submitted to the customer as part of the quality assurance documentations.

• Clad Layer Thickness Checking

Innovative equipment will be used for the CRA clad layer thickness checking, such as the Inconel 625 layer welded on the carbon steel and low alloy steel. The clad layer of the pipes or  bends will be checked continuously to meet customers’ requirements.

Nowadays, our own Butt Weld WPS/PQR already covered C.S, Low Alloy High Strength Steel, Austenitic Stainless Steel, Super Austenitic Stainless Steel, Duplex Stainless Steel and Cladding Steels, so we can also provide shop pre-fabrication; Shop hydrostatic testing pressure up to 10,000 PSI;Patent