Why chemical plants need a specialist mechanical contractor
Chemical plant construction is fundamentally different from oil & gas or general industrial work. The process fluids are aggressive — concentrated acids, alkalis, solvents, chlorinated compounds — and a single weld defect or wrong material grade can cause catastrophic corrosion failure within weeks. HAIL brings specialist capability to this challenge: our 33,000 sq.ft. fabrication workshop handles SS 304/316/316L, duplex 2205, super duplex 2507, Hastelloy C-276, Inconel and exotic alloys with full PMI traceability, ASME Section IX qualified WPS/PQR, and documented ITP from plate receipt to final hydrotest. We understand that in chemical service, metallurgy is not a specification line — it is the difference between a 20-year asset and a 2-year failure.
Chemical plant services we deliver
Acid storage tanks
Concentrated sulphuric acid, phosphoric acid, hydrochloric acid and nitric acid storage tanks in rubber-lined CS, SS 316L, Hastelloy or FRP-lined construction. Turnkey scope: civil foundation, tank fabrication, erection, piping, instrumentation and hydrotesting.
Chemical reactors & vessels
Agitated reactors, autoclaves, crystallisers and process vessels for batch and continuous chemical production. Glass-lined, rubber-lined or alloy-clad construction per process requirements. ASME U-stamp certification available.
Chemical process piping
Process piping for corrosive and hazardous chemical services per ASME B31.3. Materials include SS 316L, duplex, Hastelloy, CPVC, PVDF, PTFE-lined and rubber-lined piping. Full radiography, hydrotest and passivation.
Heat exchangers & condensers
Shell-and-tube heat exchangers, plate heat exchangers and condensers for chemical duty. Exotic tube materials (titanium, Hastelloy, duplex) with CS or alloy shells per TEMA standards.
Structural steel & platforms
Pipe racks, equipment platforms, maintenance access structures, staircases and handrails for chemical plants. Hot-dip galvanised or coated per corrosive atmospheric conditions. Fabrication per IS 800 / AISC 360.
Column erection & heavy lift
Distillation columns, absorption towers, scrubbers and stripper columns for chemical separation processes. Erection using HAIL-owned 200/100/50/20 MT crane fleet with engineered lift studies.
Chemical industry sectors we serve
HAIL provides mechanical and EPC services across the full spectrum of the chemical industry in India. Each sub-sector has unique process conditions, material requirements and safety protocols — and we adapt our fabrication, welding and quality systems to match.
Phosphoric acid plants
Wet-process and thermal phosphoric acid production facilities. Acid storage tanks, reaction vessels, evaporators, filter feed tanks, gypsum handling systems. Materials: rubber-lined CS, SS 316L, Hastelloy C-276 for concentrated acid service. Reference: Krishna Phoschem, Jhabua MP.
Chlor-alkali plants
Caustic soda, chlorine and hydrogen production facilities using membrane cell technology. Brine treatment equipment, cell room piping (titanium/PVDF), caustic storage tanks (CS with stress-relief), chlorine handling systems, HCl synthesis units. Corrosion-resistant fabrication is critical throughout.
Methanol & formaldehyde plants
Methanol storage tanks, formaldehyde reactors, absorbers, distillation columns and off-gas systems. SS 304/316 fabrication for process equipment, CS for storage with appropriate coatings. Integration with downstream resin and adhesive plants.
Specialty & fine chemicals
Multi-purpose batch reactors, solvent recovery systems, distillation trains, scrubbers and effluent treatment plants for agrochemicals, dyes, pigments, pharmaceutical intermediates and performance chemicals. SS 316L and glass-lined reactor installation.
Inorganic chemicals
Sulphuric acid plants (contact process), aluminium fluoride, sodium silicate, calcium carbide and industrial salt facilities. Acid-resistant brick lining, lead-lined vessels, acid-proof piping and fume extraction ductwork.
Petrochemical downstream
Ethanol, butadiene, acetic acid, phthalic anhydride and downstream polymer processing units. Pressure vessels, reactors, fractionation columns and associated piping in CS and alloy construction.
Corrosion-resistant materials and fabrication capability
Chemical plant equipment lives or dies by its corrosion resistance. HAIL's fabrication workshop is equipped to handle the full range of corrosion-resistant materials demanded by the Indian chemical industry. Our welders hold ASME Section IX qualifications for each material group, and every weld undergoes PMI verification, radiographic or ultrasonic examination, and documented ITP sign-off.
| Material | Typical chemical service | HAIL capability |
|---|---|---|
| SS 304 / 304L | Mild organic acids, alkaline solutions, water systems | Tanks, vessels, piping, structural — standard workshop capability |
| SS 316 / 316L | Moderate chloride, dilute mineral acids, pharmaceutical grade | Full fabrication — tanks, reactors, piping, electropolished surfaces |
| Duplex 2205 | Chloride-rich environments, seawater cooling, brine systems | Qualified WPS/PQR, controlled heat input welding, ferrite testing |
| Super duplex 2507 | Concentrated chlorides, hot seawater, severe pitting environments | Specialised welding with nitrogen-backed purge, impact testing |
| Hastelloy C-276 | Concentrated HCl, H2SO4, wet chlorine, mixed acid environments | Qualified welders, PMI at every weld joint, PWHT per specification |
| Rubber-lined CS | Concentrated H2SO4, phosphoric acid, HCl storage | CS tank fabrication + coordination with rubber lining sub-contractor |
| PTFE / FRP lined | Highly corrosive mixed acids, fluorine compounds | CS/SS shell fabrication, lining coordination with specialist vendors |
Reference projects in chemical plants
- Krishna Phoschem, Jhabua MP — Phosphoric acid storage tank: turnkey project covering civil ring-wall foundation, CS tank fabrication and erection for concentrated phosphoric acid service. Complete scope from site survey through hydrotest and handover.
- Nirma Ltd — Lime kiln duct fabrication: heavy-duty ductwork fabrication and erection for lime kiln operations at Nirma's chemical complex. High-temperature service requiring controlled welding procedures and post-weld heat treatment.
- Birla Copper, Dahej — Ammonia tank dismantling: full decommissioning EPC for ammonia storage tank at Birla Copper's integrated copper smelter complex. Gas-freeing, purging, reverse-jacking dismantling methodology with zero-incident execution in a live operating facility.
- Ostwal Phoschem (India) Ltd, Dahej: ammonia tank decommissioning supporting the phosphoric acid production value chain. Hazardous material handling with full PTW compliance and environmental safeguards.
Why HAIL for chemical plant construction
- Corrosion metallurgy expertise — we select and fabricate in SS, duplex, super duplex, Hastelloy, Inconel, titanium and lined construction based on actual process conditions, not generic specifications.
- Own fabrication workshop — 33,000 sq.ft. facility in Vadodara with plate rolling, welding bays, PWHT capability, radiography dark room and assembly area. No dependence on third-party fabricators for critical components.
- Full PMI traceability — every plate, pipe, fitting and weld in exotic alloy service is PMI-verified with documented material certificates traceable to mill test reports.
- ASME U-stamp and PESO certification — pressure vessels and storage tanks fabricated and stamped per ASME Section VIII Div. 1 and PESO regulations.
- Hazardous area experience — proven execution inside live chemical plants, refineries and fertiliser complexes with full PTW, gas testing, confined space entry and hot work permit protocols.
- Single-point EPC delivery — civil, mechanical, piping, structural steel, electrical, instrumentation, coatings, pre-commissioning and commissioning under one contract. No interface gaps between disciplines.
Frequently asked questions
What chemical plant services does HAIL provide?
HAIL provides full-scope mechanical and EPC services for chemical plants including acid storage tanks, chemical reactors, pressure vessels, process piping in exotic alloys, structural steel, heat exchangers, column erection, and corrosion-resistant fabrication in SS 316L, duplex, Hastelloy, rubber-lined CS and FRP-lined equipment. We serve phosphoric acid, chlor-alkali, methanol, formaldehyde, caustic soda and specialty chemical plants across India.
What corrosion-resistant materials does HAIL fabricate?
We fabricate chemical process equipment in SS 304/316/316L, duplex 2205, super duplex 2507, Hastelloy C-276, Inconel, titanium, rubber-lined carbon steel, FRP-lined tanks, and PTFE-lined piping. Material selection is driven by the specific chemical service — acid type, concentration, temperature and chloride content. Every joint is PMI-verified with full traceability.
Does HAIL have experience with phosphoric acid plants?
Yes. HAIL delivered a turnkey phosphoric acid storage tank project for Krishna Phoschem at Jhabua, Madhya Pradesh — covering civil foundations, tank fabrication and erection for concentrated phosphoric acid service. We also executed ammonia tank dismantling at Dahej for Ostwal Phoschem (India) Ltd, which operates in the phosphoric acid value chain.
Can HAIL execute mechanical works inside operating chemical plants?
Yes. HAIL has a proven track record executing mechanical works inside live industrial facilities including IOCL refineries, fertiliser complexes and chemical plants. We maintain full PTW (Permit-to-Work) compliance, dedicated safety officers, JSA per task, gas testing protocols and a zero major incident record in hazardous operating environments.