Nucor Skyline

Nucor Skyline has vast experience in manufacturing pipe piling products for the North American steel foundation industry. With our strategically located manufacturing plants, we can service the needs of any public or private project throughout the country.

  • 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

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.

Manufacturing Process

Electric Resistance Welded (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 form a bond. The longitudinal ERW seam does not require filler metal.

Rolled & Welded Pipe, Spiralweld Pipe, or ERW Pipe

An electric resistance welded (ERW) pipe is one of the most versatile tools in the industry. However, ERW pipes are only one of the numerous types of pipe available. It is important to know the differences between each type of pipe so that the right pipe can be chosen.

Rolled and welded pipe is made from sections of steel plate, rolled into cans. The seam of the can is welded and then individual cans are welded together to make the finished pipe. Rolled and welded pipe can be made in diameters of up to 16 feet and over 2.0 inches in thickness.

Spiralweld pipe, like ERW pipe, is also manufactured from steel coil. The difference is the coil is wound at an angle, so the weld runs around the outside of the pipe in the shape of a helix. This allows for a lot more variation in diameter and thickness than ERW pipe. Spiralweld pipe is most commonly used for pipe diameters between 24 in. and 120 in. and for thicknesses of 1.0 in. or less.

In contrast, an ERW pipe is made by rolling metal and then heating the two edges with electricity so they form a weld down its length. This forms a “seam,” differentiating it from a seamless pipe. 

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. 

Download Product Manual

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