In September and October 2025, STAUFF India successfully completed the complete re-piping of a steel mill - within a maximum time window of 45 days. The challenge: no time reserve, complex systems and the highest safety requirements.
Thanks to the full package service and the innovative STAUFF Form EVO jointing technology, the project was not only completed on time, but also with guaranteed zero leakage. This project shows how STAUFF creates strategic added value for the industry as a full-service provider.

The initial situation was anything but ideal. The existing pipework was over a decade old, heavily worn and affected by corrosion. Leaks were part of everyday life and the maintenance team was constantly on call to repair damage during ongoing operations.
Particular problems:

• Complex pipework made it difficult to dismantle individual pipes.

• The majority of the connections were welded and did not meet any standard.

• Repairs during operation were often impossible due to cramped installation spaces and high temperatures

STAUFF India took over all steps from a single source: from dismantling the old pipes and producing new pipes to installation, cleaning, leak testing and final acceptance.
The most important key points:

• Use of the STAUFF Form EVO tube forming system and standardised components from the STAUFF Connect range.

• Guarantee: Zero leakage and maintenance free at operating pressures up to 300 bar.

• Components manufactured locally in India ("local content") for maximum efficiency.

Traditionally, welding has been the first choice in safety-critical applications such as steel mills. However, welding requires specialised qualifications, extensive testing and is time-consuming.
With STAUFF Form EVO, STAUFF offers a safe, economical and reproducible alternative:

• Time saving: 7-10 minutes per tube compared to 30 minutes for welding (including time-consuming testing).

• Simple inspection: caliper gauge instead of X-ray inspection.

• Independent of skill level: Operation of the forming machine without special qualification.

• Flexibility: Standardised components enable later adaptations or extensions.

Initially, there was a great deal of scepticism - the maintenance team had previously only been familiar with welding. However, the simple operation of the forming machine and its efficiency quickly won them over. Today, not only the operators are enthusiastic, but also other service providers involved who would also like to use forming technology in the future.
The project was a milestone for STAUFF India: the positive experience led to the decision to further expand the Piping Division.

With STAUFF Form EVO, STAUFF is setting new standards in hydraulic and fluid technology. The system is designed for tube dimensions from 6 mm to 42 mm and offers maximum safety and cost-effectiveness.
The advantages at a glance:

• Significant time savings during installation.

• Simple testing without complex procedures.

• High operational reliability for critical applications.

• Flexibility for conversions and extensions.

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