Oil Tanker Catwalk Retrofit Project in Port Arthur, TX
Oil Tanker Catwalk Retrofit Project in Port Arthur, Texas
A few years back, Marco Specialty Steel completed a custom catwalk retrofit project for two sister oil tankers operated by a major energy company. The work began when Marco Specialty Steel’s fabrication manager and draftsman traveled from Houston to board the first vessel in Port Arthur, Texas.
The team took detailed field measurements, reviewed the existing catwalk layout, and provided recommendations for the retrofit installation. After the measurements were completed, Marco Specialty Steel prepared updated fabrication drawings, erection drawings, and a delivery schedule for the customer’s review and approval.
The project was originally specified using Coast Guard-approved phenolic fiberglass grating. During the review process, however, the customer changed the material specification to galvanized steel bar grating. Because Marco Specialty Steel supplies and fabricates multiple types of grating, the team was able to revise the project quickly and continue without requiring the customer to restart the sourcing process with another vendor.
Project Details
- Location: Port Arthur, Texas
- Industry: Oil and gas
- Application: Oil tanker catwalk retrofit
- Project scope: Two sister vessels
- Original specification: Coast Guard-approved phenolic fiberglass grating
- Final material: Galvanized steel bar grating
- Services provided: Field measurements, recommendations, drawing development, fabrication, shop layout, inspection preparation, packing, and delivery coordination
Project Requirements
The customer needed fabricated catwalk grating systems for two existing oil tankers. The project required more than supplying standard grating panels because the new sections had to correspond with the existing vessel layouts.
The first vessel was available in Port Arthur for a limited period, so Marco Specialty Steel coordinated a site visit while the tanker was in port. The fabrication manager and draftsman boarded the vessel, documented the catwalk areas, and took the measurements required to develop the fabricated system.
Marco Specialty Steel then used the field information to prepare updated drawings and an erection plan showing how the grating sections would be positioned on the vessel. The drawings and proposed delivery schedule were submitted to the customer for review before production began.
Project Challenges: Specification Change from Fiberglass to Steel Grating
The project was initially developed around Coast Guard-approved phenolic fiberglass grating.
During the drawing review process, the customer changed the specification to galvanized steel bar grating. The customer anticipated that this change might require restarting the sourcing process with another supplier.
Because Marco Specialty Steel supplies and fabricates both fiberglass and steel grating products, the same team was able to revise the drawings, update the material requirements, and convert the project from phenolic fiberglass to galvanized steel bar grating within a matter of days.
This flexibility allowed the project to continue without transferring the measurements, drawings, and project information to another fabricator.
Galvanized Bar Grating Fabrication
Once the revised drawings were approved, Marco Specialty Steel began fabricating the galvanized bar grating sections for the first vessel.
The grating was produced according to the field measurements and identified for its intended location within the vessel’s catwalk system. This required careful coordination between the approved drawings, individual fabricated sections, inspection layout, packing, and final delivery.
Marco Specialty Steel’s Houston facility provided the space required to accommodate the large fabrication project and prepare the complete order for inspection.
Full Shop Layout and Customer Inspection
Before shipment, the customer requested a visual inspection of the completed catwalk grating.
Marco Specialty Steel laid out all of the fabricated grating sections in its Houston facility according to their planned vessel locations. This gave the customer’s representatives an opportunity to inspect the overall system before the material was packed and shipped.
The fleet operations engineer superintendent traveled from overseas to attend the inspection with another superintendent. After reviewing the layout and fabricated sections, the representatives approved the grating for shipment.
The ability to arrange the entire project within Marco Specialty Steel’s facility gave the customer additional confidence in the finished system before it was sent to meet the vessel.
Packing and Delivery Coordination
After approval, Marco Specialty Steel packed the fabricated grating according to its intended location on the tanker.
The sections were organized to support identification, lifting, handling, and placement once the material was loaded onto the vessel. This helped keep the components grouped according to the erection drawings and their planned positions within the catwalk system.
Although the first vessel had been measured in Port Arthur, its operating schedule later required the completed grating to be shipped to California. The order was sent there to meet the tanker as it traveled between South America and Alaska.
Second Sister Vessel Catwalk Retrofits
Following the successful installation of the first catwalk system, the customer instructed Marco Specialty Steel to begin production for a second tanker in the same fleet.
Because the two vessels were sister ships with nearly identical layouts, Marco Specialty Steel was able to use the completed project as the basis for the second set of drawings and move into production without repeating the entire field-development process.
The second galvanized bar grating system was fabricated, packed, and shipped to a Texas port, where it was loaded onto the vessel.
Completed Catwalk Retrofits for Two Sister Vessels
This project required field measurements aboard an operating oil tanker, drawing development, a major material change, custom grating fabrication, full shop layout, customer inspection, specialized packing, and delivery coordination across multiple ports.
Marco Specialty Steel’s ability to supply and fabricate both fiberglass and steel grating allowed the project to continue after the specification changed. Its large Houston fabrication facility also made it possible to lay out the complete order for inspection before shipment.
The successful completion of the first vessel led directly to the fabrication of a second catwalk grating system for its sister ship.
This project demonstrates Marco Specialty Steel’s ability to coordinate field measurements, drawing development, grating fabrication, shop inspections, specialized packing, and delivery for complex marine access projects.
Need fabricated grating for a retrofit or industrial access project? Send Marco Specialty Steel your drawings, specifications, or project requirements.