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Rectangular Fabric Expansion Joint for a Heat Recovery System at a Cement Plant

March 15, 2022

Ptp fabric expansion joint 147379

U.S. Bellows, Inc. designed and fabricated this rectangular fabric expansion joint for a heat recovery system at a cement plant in Indiana. The unit was fabricated with a high-temperature PTFE fabric belt and carbon steel frame. The dimensions are 197″ in length, 118″ in width, and 18″ face-to-face. The expansion joint is designed for an operating temperature of -20°-400°F at +/- 60″ water column and 1″ of axial compression and lateral offset. A dye-penetrant exam was performed on all welds before shipment.

Fabric expansion joints are often used in ducts that carry hot gases at low pressures. The major design parameters are the temperatures and flow rates of the gases and the amount and abrasiveness of solids suspended in the gases. Rectangular fabric expansion joints are also used in power plant ducting that requires joints from the boiler or economizer outlet to the chimney.

Also, they can be used on ducting to the coal pulverizers and the furnace-air inlets. Combustion turbines will also use these types of joints in exhaust and heat-recovery ducts. The primary duct movement this type of joint absorbs is axial expansion and contraction due to temperature changes. The expansion joint designer can also design for lateral and angular movements. Elastomers and Plastomers are the basic flexible materials used to construct the belting material for these joints. These sheets can be used in combination with woven glass, metal wire, fluoroelastomers, insulation, and other materials for use in applications where there may be abrasive material, condensate, acids, and other particles that could reduce the expected life of the joint. Our experienced engineers are also skilled in the various methods and fasteners to connect the belting material to the metal frames of the expansion joint.

This expansion joint was designed for a cement plant for one of the largest building material manufacturers worldwide. Such facilities make products ranging from fly ash, slag, masonry, white, specialty and oil well cements for use in commercial construction, residential construction, and industrial applications.

USB REF. ORIGINAL POST 03132017

26′-10″ Long Universal Expansion Joint & Ductwork for a Chemical Plant

February 16, 2022

Us bellows universal expansion joint 144495

Type:	Universal Expansion Joints with Ductwork
Size:	322″ Centerline-to-Centerline \| 48″ Diameter
Material:	304 Stainless Steel \| Carbon Steel
Design	400°F Operating Temp. @ 91 psig \| 3.3″ Lateral
Testing:	100% Dye-Penetrant \| PMI \| Hydro-tested

U.S. Bellows custom designed this 26 ft. -10 in. long universal expansion joint with ductwork for a chemical plant. The bellows, ductwork, and flanges were fabricated from 304 stainless steel and the rest of the components from carbon steel. The unit is designed for 48″ diameter piping with an operating temperature of 400°F at 91 psig and 3.3″ of lateral deflection. The expansion joint was completed in 12 weeks and was 100% dye-penetrant, PMI, and hydro-tested before shipment. Chemical plants for which these are typically required process chemicals such as ethylene oxide/glycols, toluene diisocyanate, methylene diphenyl isocyanate, hydrochloric acid, polyether polyols, butanediol, GBL, n-methyl pyrrolidone, tetrahydrofuran, 2-pyrrolidone, PVP/PVPi, specialty amines, aniline, acetylene, surfactants, polytetrahydrofuran, and methylamines. The end products include furniture, automotive antifreeze, foams, carpets, construction, steel pickling, oil well acidizing, biodegradable plastics, lithium-ion battery production, pharmaceuticals, agriculture, gas treatment, water treatment, toothpaste, detergent, spandex fibers, engineered high-performance plastics, and animal feed.

U.S. Bellows has the scale and manufacturing agility to produce expansion joints and ductwork ranging in order size from a small scale of sub-1000 of dollars to upwards of 1M dollar large capital projects. We regularly support overnight lead times and tight project deliverables with evolving project requirements per the client and site needs. Last month, over half of our production capacity, was dedicated to this kind of work. A glimpse into our capabilities is outlined below from some projects we did last year:

– Refurbished 6, 48″-64″ diameter refractory-lined expansion joints for a large Houston refinery during a 45-day turnaround
– Completed a large ducting project for a major chemical facility in Texas with on-time delivery
– In the last 6 months, 40% of our expansion joint jobs have shipped in 2 weeks

We invite you to visit our facility and meet our team to get a first-hand look at our capabilities for your upcoming projects.

US-B REF. ORIGINAL POST 11122019

Universal Expansion Joints Custom-Designed for a Hot Air Blower

July 12, 2021

These universal expansion joints were custom-designed with guided tie rods, internal liners, and bellows protection covers for a hot air blower. These expansion joints are used in a plant that manufactures tires for cars and light-duty trucks. High Heat is required in the manufacturing process to vulcanize rubber to components made of steel and polyester and to also cure the rubber. The universal expansion joint can allow for large amounts of lateral deflection that can occur in more than one plane. By increasing or decreasing the distance between the two bellows by varying the length of a section of pipe spool, the designer can accommodate for the given amount of lateral deflection. These expansion joints are designed for an operating pressure of 50 psig at 383 degrees F. A total of 18 were supplied with half of the units measuring 40” dia. x 74-7/8” long x 58-1/2” overall outer dia. The rest measure 36” dia. X 60-1/4” long x 53-3/4” overall outer diameter. The bellows, flange, middle pipe, liner, and lugs are fabricated from 316/316L stainless steel. The rods, nuts, and cover are 316 stainless steel. The 40” dia. unit is designed for 0.394” axial compression and the 36” dia. unit is designed for 0.20” axial compression. Both units are designed for 0.394” lateral movement. Each expansion joint was inspected by quality control and hydraulic pressure tested before shipment. We manufacture expansion joints to relieve stress in piping systems whether the thermal movement is axial, lateral, or angular in plants such as Food Processing, Automotive, Hospital Steam Lines, Semiconductors, and other types of Green Energy plants.

US Bellows Custom-Designed Tied Universal Expansion Joints for Service at a Chemical Plant

February 9, 2021

Universal expansion joints such as these are used in chemical plants that manufacture petrochemicals (such as ethylene and styrene monomer), polymers, and building products (PVC profiles for windows, doors, and decking). The units range in length from 26” to 48” and in diameter from 8” to 20”. The bellows were fabricated from 321 stainless steel, the weld ends, pipe spools, and flanges from 304 stainless steel, and the tie rods and hex nuts from carbon steel. They are designed for temperatures ranging from -150°F to 800°F, operating pressures ranging from 50 to 240 PSIG, and 0.25” to 2.25” of lateral deflection. The expansion joints were air, soap, and bubble tested, 100% dye-penetrant tested, and hydro-tested before shipment. The universal pipe expansion joint consists of two bellows separated by a pipe section or spool. The primary purpose of this arrangement is to have a unit that will accept large amounts of lateral deflection. The amount of lateral deflection they can accept is a function of the amount of angulation each bellows can absorb and the distance between the bellows. For a given bellows element, the amount of lateral deflection capability can be increased or decreased by simply changing the length of the center spool.

Gimbal Expansion Joints for Crude Oil Pipelines in Canada

January 12, 2021

US Bellows custom-designed and fabricated universal gimbal expansion joints for 24” diameter crude oil pipelines at a power plant in Canada. The bellows are fabricated from A240 316 stainless steel bellows, the flanges are A105N carbon steel, and the plates are A516 70 carbon steel. The expansion joints are designed for a 10 degrees angular rotation at 285 PSIG up to 100 degrees F. They are designed for an angular spring rate of 4900 in-lb/dec and vertical offset of 10-1/4”. The units measure 43” x 43” x 110” and 38” x 38” x 79”.

Us bellows gimbal ej 3d model

3D Modeling was done so that our engineers can check the “fit-up” to confirm the design, perform stress analysis, or other modeling benefits prior to fabrication. We performed hydro tests, completed NDE reports, and supplied material test reports per the client requirements.

Fabric Expansion Joints Custom Designed for an Exhaust Duct at a Gas Turbine in Saudi, Arabia

June 29, 2020

Type:	Fabric Expansion Joint
Size:	70″ W x 126″ L x 17.5″ Face-to-Face
Material:	PTFE Fabric Belt \| Stainless Steel Framework
Design	Operating Temp: -20°F to 600°F \| Operating Pressure +/- 100″ Water Column Movement +/- 1″ Axial Compression & Lateral Offset Combined
Testing:	Dye Penetrant Examined \| Anchor Install Test& Q.C. Inspection

US Bellows custom-designed a rectangular fabric expansion joint with rounded corners for an exhaust duct application at a gas turbine in Saudi, Arabia. The unit is 70″ W x 126″ L x 17.5″ face-to-face; the fabric belt is PTFE and the framework is stainless steel. The expansion joint is designed for an operating temperature range from -20°F to 600°F, an operating pressure of +/- 100″ water column, and a movement of +/- 1″ axial compression and lateral offset combined. A 100% dye-penetrate exam and anchor install test were performed before shipment.

U.S. Bellows, Inc. Custom Designed a Refractory-Lined Expansion Joint for a Regenerator Application in Uruguay

April 13, 2020

$Us bellows refractory lined expansion joints 150958$

Type:	Refractory-Lined Expansion Joint
Size:	43″ Tall x 39-1/2″ Refractory Dia. (Bellows diameter 50” Dia)
Material:	Carbon Steel \| INCOLOY® 825 \| 4.75″ Thick Refractory
Design	Operating Temp: 653°F at 46 PSIG \| 0.25″ Axial Compression
Testing:	Hydro-tested \| Q.C. Inspection

U.S. Bellows engineered and manufactured this refractory-lined expansion joint for a demanding regenerator application in Uruguay, where high temperatures and abrasive process conditions required a robust and reliable expansion joint solution.

The unit measures 43 inches in height and 39-1/2 inches in Refractory diameter and was fabricated using carbon steel for the structural components not in direct contact with the temperature media, the internal components in direct contact with the high temperatures were fabricated out of Stainless steel 304H, while the bellows were manufactured from INCOLOY® 825, a nickel-iron-chromium alloy known for its excellent resistance to corrosion, oxidation, and high-temperature environments. The use of INCOLOY® 825 ensures long-term performance in harsh process conditions commonly found in regenerator systems.

To protect the expansion joint from extreme temperatures and abrasive media, the unit was lined with 4.75 inches of insulating and abrasion-resistant refractory material and 304H SS anchors. This refractory lining serves two critical purposes: it protects the bellows and metal components from excessive heat exposure and minimizes wear caused by abrasive particulate flow. This design approach significantly extends the service life of the expansion joint while maintaining reliable operation under severe process conditions.

The expansion joint bellows was designed to operate at a temperature of 653°F and a pressure of 46 PSIG, while accommodating 0.25 inches of axial compression within the piping system. These design parameters ensure that the joint can safely absorb thermal movement and mechanical stresses generated during operation, thereby protecting the surrounding piping system and connected equipment.

Quality and reliability are fundamental to all U.S. Bellows products. Prior to shipment, the expansion joint underwent hydrostatic pressure testing at 68 PSIG to verify structural integrity and pressure containment. This testing confirms that the unit meets the required performance and safety standards before installation and operation in the field.

Custom-engineered expansion joints such as this refractory-lined unit demonstrate the ability of U.S. Bellows to provide specialized solutions for high-temperature and highly demanding industrial environments. With decades of experience designing and manufacturing expansion joints for industries including refining, petrochemical, power generation, and heavy industrial processing, we continue to deliver products that combine engineering expertise, high-quality materials, and rigorous testing to ensure dependable performance.

Universal Expansion Joint with Oversized Bellows for a Crude Oil Line Application in Saudi Arabia

September 3, 2019

Type:	Universal Expansion Joints
Size:	48″ Diameter \| 77″ FTF
Material:	316 Stainless Steel \| Carbon Steel
Design	150°F Operating Temp. @ 25 PSIG \| 5.3″ Axial \| 2″ Lateral
Testing:	Hydro-tested @ 50 PSIG

US Bellows custom-designed this universal expansion joint for a crude oil line at an oil refinery in Saudi Arabia. This expansion joint was specially designed with oversized bellows to keep a smooth flow of oil along the line and avoid turbulence. The bellows were fabricated from a 316 stainless steel with all of the other components from carbon steel. The unit is 48″ in diameter and 77″ face-to-face. It is designed for an operating temperature of 150°F at 25 PSIG, 5.3″ of axial compression, and 2″ of lateral deflection. The unit was hydro-tested at 50 PSIG prior to shipment.

66″ Custom Designed Hinged Expansion Joint for a Chemical Plant in Saudi Arabia

August 19, 2019

Type:	Hinged Expansion Joints
Size:	66″ Diameter \| 39 3/8″ OAL
Material:	Incoloy 825 \| 321 Stainless Steel
Design	986°F Operating Temp. @ 73 PSIG \| 4.25° Angular
Testing:	100% Dye-Penetrant \| X-Ray \| Hydro-tested

This single hinged expansion joint was custom-designed for a chemical plant in Saudi Arabia. The bellows were fabricated from Incoloy 825 and the cover, weld-ends, hinges, and liner from 321 stainless steel. The unit is 66″ in diameter and 39 3/8″ OAL. It is designed for an operating temperature of 986°F at 73 PSIG and 4.25° of angular rotation. The expansion joint was 100% dye-penetrant tested, the bellows and pipe longitudinal seam were x-ray tested and hydro-tested prior to shipment.

Custom Tied Universal Expansion Joints for a Chemical Plant in Texas

June 17, 2019

Type:	Universal Expansion Joints
Size:	108″ Length \| 19.5″ ID
Design:	304 Stainless Steel
Material:	550°F Operating Temperature @ 15 PSIG, 5″ Lateral
Testing:	100% Dye-Penetrant \| Air, Soap, & Bubble

US Bellows custom-designed these tied universal expansion joints for a chemical plant in Texas. The units were completely fabricated from 304 stainless steel and are 108″ long with a 19.5″ ID. They are designed for an operating temperature of 550°F at 15 PSIG, 5″ of lateral deflection. The expansion joints were 100% dye-penetrant tested and air, soap, and bubble-tested prior to shipment.

Single Expansion Joints Designed for an Oklahoma Pipeline

May 13, 2019

Type:	Single Flanged Expansion Joint
Size:	10″ & 14″ NPS \| 13″ & 16-1/2″ OAL
Material:	304 Stainless Steel \| CS
Design	203°F Operating Temperature
Testing:	100% Dye Penetrant \| Hydro-tested

U.S. Bellows designed these 10″ and 14″ NPS single expansion joints for a pipeline in Oklahoma. They have an overall length of 13″ and 16-1/2″. The bellows, liners, covers, and flanges are fabricated from 304 stainless steel, and the tie rods are carbon steel. They are designed for an operating temperature of 203°F at 15 psig. The expansion joints were 100% dye-penetrant and hydro-tested prior to shipment.

80″ Long Rectangular Universal Metallic Expansion Joint Designed for a Texas Refinery

March 18, 2019

Type:	Rectangular Universal Metallic Expansion Joint
Size:	80″ Long \| 60″ Wide
Design:	304 Stainless Steel \| Carbon Steel
Material:	Operating Temp. of 170°F @ 25 psig
Testing:	Soap & Air Bubble \| 100% Dye-penetrant

US Bellows custom designed this rectangular universal metallic expansion joint for a refinery in Texas. The unit is 80″ long and 60″ wide. The bellows are fabricated from 304 stainless steel, and the flange and pipe spool are carbon steel. It is designed for an operating temperature of 170°F at 25 psig. The expansion joint was soap and air bubble tested and 100% dye penetrant tested prior to shipment.

20″ Tied Universal Expansion Joint

February 11, 2019

Expansion Joint Crated for Export

This tied universal expansion joint is fabricated from carbon steel pipe, tie rods and covers, and 304 stainless steel bellows and liners. The overall length of the expansion joint is 72″. The application of this expansion joint is to provide for large lateral movement in a propane dehydrogeneration plant. The expansion joint welds were 100% dye-penetrant examined and hydro-tested prior to shipment

In-line Pressure Balanced Expansion Joints Designed for a 58″ Pipeline at a Chemical Plant

January 21, 2019

Type:	In-line Pressure Balanced Expansion Joint
Size:	38″ F-F \| 58-1/2 Diameter
Material:	304 Stainless Steel \| Carbon Steel
Design:	725°F @ 14.22 PSIG \| 1-1/2″ Axial Compression \| 422 lb./in. Spring Rate
Testing:	100% X-Rayed \| Dye-penetrant \| Air/leak tested

US Bellows custom-designed these in-line pressure balanced expansion joints for a chemical plant in Texas. They are 38″ face-to-face and 58-1/2″ in diameter. The bellows are fabricated from 304 stainless steel with carbon steel tie rods and flange plates. They are designed for use at 725°F and 14.22 psig, with a spring rate of 422 lb/in. and 1.5″ of axial compression. The expansion joints were 100% dye-penetrant examined and air leak tested prior to shipment.

Single Expansion Joint Designed for a Refinery in Korea

December 31, 2018

Type:	Single Flanged Expansion Joint
Size:	18-1/2″ Long \| 8″ Diameter
Material:	304 Stainless Steel \| CS
Design	338°F @ 51 PSIG \| 1-3/4″ Axial Movement \| 225 lb. Spring Rate
Testing:	100% Dye Penetrant \| Hydro-tested \| X-Rayed

US Bellows manufactured this single expansion joints for a refinery in Korea. The bellows were fabricated from 304 stainless steel, and the frame from carbon steel. The expansion joint is 8″ in diameter and 18-½” long. It is designed for an operating temperature of 338°F at 51 PSIG, with an axial movement of 1¾”, and a spring rate of 225 lb./in. The bellows were 100% X-rayed, dye-penetrant examined, and hydro-tested prior to shipment.

30″ Dia. Expansion Joints Designed for an Oil and Gas Facility

December 3, 2018

30 inch Dia. Expansion Joints Designed for an Oil and Gas Facility

Type:	Single Expansion Joints
Size:	24″ F-F \| 30″ Diameter
Design:	304 Stainless Steel \| Carbon Steel
Material:	800°F @ 275 psig \| 1″ Axial Compression
Testing:	Hydro-tested

These single expansion joints were custom engineered for an oil and gas facility in Texas. The bellows, liner, and cover are fabricated from 304 stainless steel, while the flanges and tie rod assemblies from carbon steel. The units are 30″ in diameter, 24″ face-to-face and include control rods. They are designed for an operating temperature of 800°F at 275 psig and 1″ of axial compression. All expansion joints were hydro-tested prior to shipment.

36″ Dia. Externally Pressurized Expansion Joints Designed for a Power Plant in Venezuela

October 29, 2018

Type:	Externally Pressurized Expansion Joints
Size:	36″ I.D. \| 56″ OAL \| 10″ Face-to-Face
Design:	Hastelloy C-276 Bellows \| A36 CS Flanges & Spool
Material:	60 PSIG at 572°F \| 9.75″ Axial Compression
Testing:	100% Dye-Penetrant \| Hydro-Tested

U.S. Bellows custom designed externally pressurized expansion joints for a power plant in Venezuela. The units are 56″ in overall length and have a 36″ inside diameter. The bellows are fabricated from Hastelloy C-276 and the flanges and spool are A36 carbon steel. The units are designed for an operating pressure of 60 psig at 572°F and 9.75″ of axial compression. The expansion joints were 100% dye-penetrant tested and hydro-tested prior to shipment.

Thick-Wall Flanged and Flued Head Expansion Joints Designed for Boiler and Furnace Replacement

October 15, 2018

Type:	Thick-Wall Flanged & Flued Head Expansion Joints
Size:	52-7/8″ I.D. \| 83-5/8″ I.D. \| 10″ Face-to-Face
Design:	ASTM A 516-70 Carbon Steel
Material:	250″ Water Column
Testing:	100% Dye-Penetrant \| Soap & Air Leak \| Hydro-Tested

US Bellows custom-designed thick-wall flanged and flued head expansion joints for a boiler and furnace replacement at a chemical plant in Kentucky. The units were fabricated entirely from ASTM A 516-70 carbon steel. The smaller unit’s inside diameter is 52-7/8″, and the larger unit is 83-5/8″. Both units are 10″ face-to-face. They are designed for an operating pressure of 250″ water column. The expansion joints were 100% dye-penetrant tested, soap & air leak tested, and hydro-tested prior shipment.

Rectangular Metallic Expansion Joints Designed for an Exhaust Duct

September 16, 2018

Type:	Rectangular Metallic Expansion Joint
Size:	16.5″ x 14.75″ x 12″ F-F
Design:	304 Stainless Steel
Material:	Operating Temp: 800°F @ +/- 20″ WC 1″ Axial Compression \| 0.25″ Angular Rotation
Testing:	100% Dye-penetrant tested \| Soap & Air Tested

U.S. Bellows custom designed these rectangular metallic expansion joints for an exhaust duct application in Wisconsin. They are 16.5″ x 14.75″ and 12″ face-to-face. The units are completely fabricated from 304 stainless steel. They are designed for an operating temperature of 800°F at a +/- 20″ water column, with 1″ of axial compression and 0.25 degrees of angular rotation. The expansion joints were 100% dye-penetrant tested and soap & air tested prior to shipment.

Universal Expansion Joints Designed for a Tank Farm

September 3, 2018

Universal-Expansion-Joint-155090v2

Type:	Universal Expansion Joint
Size:	24″ Dia. x 48″ F-F \| 20″ Dai. x 50″ F-F
Material:	Carbon Steel \| 316 Stainless Steel
Design:	Operating Temperature: 180°F Pressure: 264 PSIG Movement: 2.75″ Lateral Deflection
Testing:	100% Dye-penetrant tested, X-rayed, Hydro-tested

High-Performance Expansion Joints Delivered for a Critical Application in Saudi Arabia

For a critical industrial application in Saudi Arabia, our team engineered and manufactured a series of high-performance expansion joints designed to meet demanding operating conditions and stringent quality requirements.

The project included 24 custom-fabricated units, with 16 expansion joints measuring 24″ in diameter × 48″ face-to-face and 8 units measuring 20″ in diameter × 50″ face-to-face. The bellows were constructed from 316 stainless steel to provide superior corrosion resistance, while the remaining components were fabricated from carbon steel for structural strength and durability.

Designed to operate at 264 PSIG and 180°F, these expansion joints accommodate 2.75 inches of lateral movement, ensuring flexibility and reliability under dynamic operating conditions. To guarantee long-term performance and safety, every unit underwent a rigorous quality assurance process, including 100% dye penetrant inspection, radiographic (X-ray) testing of the long seams, and hydrostatic testing prior to shipment.

This project highlights our ability to deliver engineered solutions that meet the highest international standards. By combining advanced manufacturing capabilities, strict quality control, and deep engineering expertise, we continue to support complex global projects with reliable, high-performance products that perform in the most demanding environments.

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