Custom Industrial Steel Stack Fabrication Services

T BAILEY LLC fabricates custom industrial steel stack systems for refineries, power generation, marine operations, water and wastewater plants, and heavy industrial facilities. For over 35 years, our team has produced engineered steel stacks built to the dimensional, structural, and code requirements that decision-stage buyers rely on.

With fabrication, surface preparation, industrial coatings, inspection, and testing all performed at our Anacortes, Washington facility, T BAILEY LLC delivers a full-service industrial steel stack fabrication solution that reduces vendor coordination, tightens schedules, and holds every phase to a single quality standard.

What an Industrial Steel Stack Does

An industrial steel stack routes combustion byproducts, process emissions, and exhaust gases away from operating equipment and out of the surrounding work environment. These systems support industrial ventilation by directing stack exhaust to the height and dispersion profile required by local air quality regulations and facility design. Steel stacks are used across the stack industry for power plants, refineries, chemical processing facilities, marine engine exhaust systems, and manufacturing operations where reliable removal of industrial exhaust is essential to safe and compliant operation. Because exhaust stacks operate under thermal, structural, and corrosive loads, the fabrication standard behind them matters as much as the design.

Steel Stack Fabrication Capabilities

T BAILEY LLC fabricates custom exhaust stacks and industrial stack systems to project-specific dimensional and material requirements. Our steel fabrication shop is equipped to scale production from compact shop-built sections to large field-erected assemblies, with capabilities that cover the range most industrial buyers need:

• Services: Stack fabrication, repair, and replacement
• Materials: Carbon steel and stainless steel, including stainless steel stack and stainless steel exhaust stack fabrication for corrosive or high-purity applications
• Length: Over 100 feet, with field-assembled options for longer stack runs
• Diameter: Up to 15 feet shop-fabricated complete, unlimited for field-assembled stacks
• Wall Thickness: 3/8″ to 4″

If your project requires specifications outside these standard ranges, our team can adapt the fabrication process to your design intent, including custom hardware, stiffener configurations, and integrated structural features.

In-House Blasting and Coating for Steel Stacks

A defining advantage of working with T BAILEY LLC is direct, on-site access to our industrial coatings division. The coatings facility sits on the same grounds as the fabrication shop and is organized as a large bay with dedicated rooms for each phase of the coating process, including a surface preparation room, a paint application room, and a heated drying room. Rails in the floor allow stacks to move through each phase efficiently, supporting tight schedule control and consistent coating quality.

Coating and surface preparation services for industrial steel stacks include pre-washing per SSPC SP1, machine and manual blasting to the specified surface profile, metallizing with zinc or aluminum, and finish coatings selected for the operating environment, including high-temperature paints, urethanes, epoxies, enamels, and vinyl ester systems. Keeping coatings in-house reduces freight risk between vendors, eliminates handoffs that introduce schedule slippage, and gives clients a single point of accountability from raw plate through coated, inspected stack.

Quality Control and Testing for Industrial Steel Stacks

Every industrial steel stack we fabricate moves through a comprehensive quality control program before it leaves our facility. Our in-house inspection and non-destructive examination team operates full-time and is led by AWS Certified Welding Inspectors and a CWB Certified Welding Supervisor.

Testing and inspection capabilities include visual inspection with step-by-step process monitoring, radiographic testing (RT), ultrasonic testing (UT), dye penetrant testing (PT), magnetic particle testing (MT), heat treating and stress relieving, hardness testing, impact testing, positive material identification (PMI), full blast and lining profile measurement, dry film thickness testing, environmental monitoring and reporting, adhesion testing, and lining continuity (holiday) testing.

This level of inspection ensures that every stack we deliver is built to code, meets the specifications referenced in your fabrication package, and is ready for the structural, thermal, and regulatory demands of the receiving facility.

The Steel Stack Fabrication Process

T BAILEY LLC manages the full steel stack fabrication process in-house, from detailing through final coating. A typical project moves through the following sequence:

1. Detailing: Our detailers work from your steel stack design and engineering drawings to produce shop-ready details aligned with your project requirements.
2. Cutting and rolling: CNC plasma cutters size the steel plate, and our plate rollers form the plate into cylindrical sections.
3. Welding and assembly: Qualified welders seal the longitudinal seams of each cylinder and join cylinders into full stack sections using approved weld procedures.
4. Hardware fitting: Where the design calls for it, our team installs manways, nozzles, stiffener rings, lifting lugs, helical strakes, and other integrated stack hardware.
5. Blasting and coating: The completed stack moves into our coatings facility for surface preparation and application of the specified coating system, followed by final inspection and dry film thickness verification.

Industries and Applications We Serve

T BAILEY LLC has fabricated industrial exhaust stacks for clients across oil and gas, refining and petrochemical, power generation, water and wastewater, marine and shipyards, chemical processing, manufacturing, and government and infrastructure projects. These sectors rely on industrial steel stack systems to manage exhaust loads, meet air quality requirements, and support uptime in operating environments where reliability is not optional.

Certifications and Standards

T BAILEY LLC maintains the certifications required to fabricate industrial steel stacks for regulated industrial, marine, and infrastructure applications. Our credentials include:

• AWS D1.1 certification: Structural welding code compliance across all stack fabrication and assembly
• SSPC QP3 certification: Certified shop application of industrial coatings
• AISC Certified Fabricator: With all three Sophisticated Paint Endorsements through the AISC Certified Fabricator program
• CWB Certification: Per CSA W47.1 for projects serving the Canadian market
• DOT certifications: Across multiple states, supporting transport of oversized fabricated stack components

These certifications, combined with full in-house inspection and testing at every stage, mean that every industrial steel stack we deliver is built to code, documented through inspection, and ready for the operating environment it ships into.

Built in Anacortes, Shipped Across the USA

Our 30-acre fabrication facility in Anacortes, Washington gives clients a strategic logistics advantage for industrial steel stack delivery. The site sits 5 miles from a deep-water port, 7 miles from a rail spur, and 10 miles from Interstate 5, supporting flexible shipping options for oversized stack sections. We offer truck delivery using in-house drivers and trusted third-party carriers, rail service throughout the United States and Canada, and barge or steamship delivery for projects in Alaska, Hawaii, and other water-accessible locations. For each project, our team can provide a cost analysis across the available shipping options to help you select the most effective route. As a steel construction company with field erection capability, we also support installation scopes for stacks that exceed standard shop dimensions.

Whether your project calls for a single custom exhaust stack or a multi-section industrial steel stack system fabricated to tight specifications, T BAILEY LLC has the capabilities, certifications, and project history to deliver. Contact T BAILEY LLC today to discuss your industrial steel stack fabrication requirements.