Nucor Skyline

Electric resistance welded (ERW) pipe is made from steel coil and the weld seam runs parallel to the pipe. The width of the coil is the same as the circumference of the pipe so diameters are limited to 24 inches. However, because the manufacturing process is fast, it is ideal for large production runs of small (<= 24 in.) diameter sections.

  • OD: From 2-3/8” to 24”; Thickness: Up to 0.625”
  • Custom Lengths and Thicknesses
  • Custom Fabrication Services
  • In-house and Third-Party Testing Capabilities
  • Made in the USA

Manufacturing Process

ERW pipe is manufactured by cold forming a flat steel strip into a rounded tube and passing it through a series of forming rollers to obtain a longitudinal seam. The two edges are then simultaneously heated with a high frequency current and squeezed together to produce a bond. The longitudinal ERW seam does not require filler metal while impurities in the heat affected zone are extruded during the welding process.

A few advantages to note with ERW pipe:

  • There are no fusion metals used during the manufacturing process. This means that the pipe is extremely strong and durable.
  • The weld seam cannot be seen or felt. This is a major difference when looking at the double submerged arc welding process, which creates an obvious welded bead that might need to be eliminated.
  • With the advances in high-frequency electric currents for welding, the process is far easier and safer.



Incoming coils are peeled and unwrapped for presentation into the flattener rolls. Flattening removes the coil set to produce a flat steel strip.

ERW Coil Joining


Coil ends are joined together with a butt weld to produce a continuous strip.

ERW Edge Trimming


Slitter blades and edge milling trims strip edges to provide the precise strip width required during the forming and ERW seam welding process.

ERW forming


The forming process begins at the Breakdown Pass where the material is gradually bent from a flat steel strip into a rounded tube for presentation to the ERW seam welder.

ERW Welding


A high frequency electrical current flows through contact tips into the strip edges to produce the heat required for bonding the strip edges together as the material passes through the weld roll stand.

ERW Quality Control


Once the welding is complete, the finished pipe is visually inspected by Quality Control (QC) and, if required, Ultrasonic (UT) testing is performed to ensure the weld is defect-free.

ERW Pipe Sizing


The Sizing Section squeezes the welded pipe into the precise roundness, outer diameter, and straightness tolerances specified by the customer.

ERW Pipe Cutting


The flying cut-off saw attaches to the pipe as it is being produced and cuts the pipe to the length specified by the customer.

Case Study: Kosciuszko Bridge

Case Study: Kosciuszko Bridge

Learn about a new bridge span utilizing ERW pipe piles brings traffic relief to congested Brooklyn 

Download Case Study

Pipe Brochure

Pipe Brochure

Learn about our comprehensive line of steel pipe products. 

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Technical Product Manual

Technical Product Manual

Get all the information you need about Nucor Skyline's complete line of steel foundation products. 

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