Client Background
The client wanted a complete ∅12ft large steel ball delivered in one piece. A regular 20ft or 40ft container could not take it, and the only alternative was a flat rack, which did not fit the project budget.
Project Details
- Location
- Santa Fe, United States
- Product range
- Large Steel Balls
Customer Pain Points
- An entire ∅12ft sphere exceeded conventional container freight
- Flat rack shipping pushed the project over budget
- Any segmented solution still had to close into a true sphere on site
Our Solution
The client decided to cut the sphere into quarter sections shipped in a regular 40ft container. Two ribs were welded to each edge of every quarter sphere as an internal structure for supporting and connecting the parts back into a complete sphere.
Manufacturing Process
The ribs were made of AISI 304 stainless flat steel bar, bent, 5mm (6GA) thick and 75mm (3 inch) wide. Holes were drilled in the ribs so the structure could be fixed by bolts during on-site assembly.
Supply Chain Coordination
The client provided the full instruction for loading the 40ft container, and the sections were loaded to that plan.
Quality Control
Incoming material
Alloy and sheet thickness are checked against the order before any blank is cut.
Forming check
Diameter and wall are measured after pressing, spinning or water pressuring.
Weld and grind
The equator weld is inspected, then welds and burrs are ground off before finishing.
Surface inspection
Every piece is inspected for scratches, dents and polish consistency under light.
Packing
Protective packing is built around the diameter and weight, and photographs are sent before dispatch.
Final Result
The sphere reached site in a standard 40ft container and was assembled from quarter sections.
Customer Benefit
Segmenting the sphere removed the flat rack premium from the budget without changing the finished diameter.
Project Gallery
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Send the drawing or the concept. We will confirm the forming route, the segmentation if any, and the freight mode before you commit.