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Tag: Blogs

116″ Universal Expansion Joint for a Water Supply System in California
August 31, 2026

116" Universal Expansion Joint for a Water Supply System in California

Type: Universal Expansion Joint
Size: 116″ in diameter/60″ long
Material: AL6XN Stainless Steel/Carbon Steel
Design: 100°F at 220 PSIG, 9″ axial compression
Testing: Dye penetrant, radiographic, and hydro tested

U.S. Bellows custom-engineered and manufactured this impressive 116″ reinforced universal expansion joint for a water supply system in California. Measuring 116″ in diameter and 60″ in overall length, the unit demonstrates U.S. Bellows’ ability to design and fabricate large-diameter expansion joints for demanding infrastructure applications.

The bellows and pipe spool were fabricated from corrosion-resistant AL-6XN stainless steel, while the flanges were manufactured from carbon steel. The bellows were reinforced with AL-6XN round bar in the convolutions to contain the pressure at that volume, as the expansion joint was designed for an operating temperature of 100°F at 220 PSIG and engineered to accommodate 9″ of axial compression.

Before shipment, the completed assembly underwent extensive nondestructive examination and performance testing, including dye penetrant testing, radiographic testing, and hydrostatic testing. These quality-control measures verified the integrity of the welds and confirmed that the expansion joint met the project’s performance requirements.

U.S. Bellows has designed and manufactured engineered expansion joints since the 1960s. The company provides custom metallic, fabric, and rubber expansion joints, along with clamshell bellows, pressure-balanced assemblies, and fabricated ductwork for complex piping and ducting systems. Its engineering capabilities include design in accordance with EJMA equations and applicable ASME standards, as well as in-house finite element analysis for specialized applications.

As a longtime member of the Expansion Joint Manufacturers Association, U.S. Bellows combines specialized engineering, extensive fabrication capabilities, comprehensive testing, and field support to deliver reliable solutions for water infrastructure, refining, chemical processing, power generation, marine, offshore, and pipeline applications. The company also offers emergency engineering, manufacturing, inspection, installation support, and repair services to help customers minimize downtime during critical plant outages and system failures.

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Gimbal Expansion Joints for Crude Oil Pipelines in Canada
April 29, 2026

Gimbal Expansion Joints Fabricated for Crude Oil Pipelines in Canada

U.S. Bellows custom-designed and fabricated 24-inch universal gimbal expansion joints for crude oil pipelines at a power plant in Canada, delivering a robust solution for managing angular movement and system stress.

The bellows were manufactured from ASTM A240 Type 316 stainless steel, providing excellent corrosion resistance and durability. The flanges were fabricated from A105 carbon steel, and the gimbal assemblies were constructed from A516 Grade 70 carbon steel, ensuring structural strength and reliability under demanding operating conditions.

These expansion joints were engineered to accommodate 10° of angular rotation at 285 psig and temperatures up to 100°F. The design includes an angular spring rate of 4,900 in-lb/degree and allows for a vertical offset of 10-1/4 inches, supporting system flexibility while maintaining load control. The overall dimensions of the units are 43″ x 43″ x 110″ and 38″ x 38″ x 79″.

Us bellows gimbal ej 3d model

Advanced 3D modeling was utilized during the design phase to verify proper fit-up within the system, perform Finite Element Analysis (FEA) on critical components, and provide the customer with detailed models for integration into their plant design prior to fabrication.

To ensure quality and compliance, each unit underwent hydrostatic testing, non-destructive examination (NDE), and was delivered with complete Material Test Reports (MTRs) in accordance with the client’s specifications.

This project highlights U.S. Bellows’ capability to deliver high-performance, custom-engineered expansion joints supported by advanced analysis, rigorous testing, and value-added engineering services.

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U.S. Bellows Emergency Response Team Refurbishes a Universal Expansion Joint on a Rush Basis for a Chemical Plant in Louisiana
June 13, 2016

U.S. Bellows Emergency Response Team Refurbishes a Universal Expansion Joint on a Rush Basis for a Chemical Plant in Louisiana

Saturday morning of Memorial Day weekend, the US Bellows team received an emergency request from a large chemical plant who needed to refurbish an expansion joint by replacing both of the bellows. Within 30 minutes, the customer had a response and the project was under way.

US Bellows engineers consulted with the customer and requested the unit be shipped to the facility immediately. After receiving the expansion joint, the team performed a positive material identification (PMI) test. US Bellows assessed the expansion joint and determined the 316 stainless steel bellows could be refurbished. Once the results were concluded, engineering drawings and calculations were finalized.

US Bellows made certain that, despite the Holiday weekend, a skilled team of engineers, fitters, welders and quality control personnel were all involved to ensure the success of the project. The customer service and project success rates are unparalleled because US Bellows has the expertise and the tools we need to get it done right, the first time.

As with any last minute project, there were some unforeseen challenges. However, this didn’t stop the completion of the project, or even slow it down! The 30″ diameter universal expansion joint was refurbished and shipped back to the customer within 24 hours. The unit is back in service at the chemical plant with minimal down time due to the fast-acting U.S. Bellows team.

If you have an emergency request, including field service needs, please call us on our Emergency Hotline at (800) 787-5914 or via our online emergency request form

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Metallic Universal Expansion Joints for a Wisconsin Chemical Plant’s Emergency Shut Down
September 20, 2006

Metallic Universal Expansion Joint for a Wisconsin Chemical Plant's Emergency Shut Down
A customer’s existing expansion joint failed and caused a plant to shut down. They required an immediate replacement joint. This universal expansion joint order was placed, designed, and fabricated in just one day. The order came in at 8:30 am on Saturday, Labor Day weekend, and was shipped at 4:00 pm, which minimized the time of the plant shut down. This universal expansion joint is 96″ in overall length, 20″ inside diameter, and can absorb 3.25″ lateral movement. A 100% dye-penetration test and a hydro-test were performed to ensure quality.

 Metallic Universal Expansion Joint for a Wisconsin Chemical Plant's Emergency Shut Down  Metallic Universal Expansion Joint for a Wisconsin Chemical Plant's Emergency Shut Down
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