Cold Cutting Services in Abu Dhabi | Spark-Free Pipe Cutting for Oil & Gas Facilities

Cold cutting is a mechanical pipe and vessel cutting method using carbide-tipped tools that cut through metal without generating sparks, flames, or significant heat. It’s called “cold” because material temperature remains near ambient (unlike thermal cutting methods that create temperatures exceeding 1,000°C). The process uses split-frame machines clamping around installed pipes, with rotating cutting tools progressively removing material to create clean, precise cuts. Cold cutting is essential in oil & gas facilities and petrochemical plants where explosive atmospheres prohibit thermal cutting methods.

Cold cutting costs in Abu Dhabi vary by pipe size, wall thickness, and material type. Small bore pipes (1″-6″) typically cost AED 1,500-3,000 per cut. Medium pipes (8″-24″) range from AED 3,000-8,000 per cut. Large diameter pipes (24″-48″) cost AED 8,000-20,000 per cut. Extra-large pipes (48″+) may exceed AED 20,000-50,000 per cut. Stainless steel and exotic alloys command 20-100% premiums over carbon steel base rates. Confined space work, elevated locations, and emergency mobilizations add 15-30% to base pricing. Multiple cuts on the same project receive reduced per-cut rates as mobilization costs are amortized.

Cold cutting becomes mandatory in several scenarios: work within 15 meters of hydrocarbon storage or process equipment, operations in classified hazardous areas (Zone 0, 1, 2 per IEC standards), facilities unable to achieve gas-free conditions, adjacent to live piping containing flammable materials, tank farms and loading terminals, refineries during normal operations, offshore platforms, and any location where hot work permits cannot be obtained. ADNOC facilities and OSHAD-regulated sites often require cold cutting for safety and regulatory compliance.

BIJER’s cold cutting equipment handles pipes from 1-inch to 120-inch diameter. Small bore split-frame machines cover 1″-12″ pipes common for instrument and utility lines. Medium machines handle 12″-48″ process piping. Large-diameter systems cut 48″-120″ transfer pipelines and cross-country lines. Wall thickness capacity extends to 3 inches (80mm) with standard equipment, and specialized heavy-duty machines can cut thicker walls. We cut all common materials: carbon steel (ASTM A106, API 5L), stainless steel (304, 316, duplex), alloy steels, and exotic materials (Hastelloy, Inconel, Monel).

Cutting time depends on pipe diameter, wall thickness, and material. A 4-inch carbon steel pipe with 0.25″ wall cuts in approximately 10-15 minutes. A 24-inch pipe with 0.5″ wall requires 30-45 minutes. Large 48-inch pipes with 1″ walls may take 2-3 hours. These times include machine setup, cutting operation, and quality verification. Total project duration includes mobilization (1-4 hours), permit acquisition (same day for cold work), cutting execution, and demobilization (1-2 hours). Emergency mobilizations can complete single cuts within 6-8 hours from initial call.

No. Cold cutting requires atmospheric pressure conditions. The split-frame machine must clamp securely around the pipe, which is impossible on pressurized systems. Additionally, cutting through a pressurized pipe would violently release the contained fluid, creating extreme safety hazards. For connections to live systems, we provide cold cutting for hot tap preparation work—cutting coating, preparing weld surfaces, and creating access points for hot tapping equipment. Once the hot tap fitting is welded and the line is drilled under pressure, cold cutting can prepare downstream connections safely.

Cold cutting machines can perform both straight cuts and beveled cuts in a single operation. Standard cold cutting creates a square, perpendicular cut. Beveling adds an angled edge (typically 30° or 37.5°) required for weld preparation per AWS specifications. BIJER’s equipment adjusts cutting tool position to create bevels simultaneously with the cut, eliminating the need for separate beveling operations. This capability delivers weld-ready pipe ends without additional processing, reducing project duration and costs.

Yes. BIJER offers complete flange integrity services combining cold cutting and flange facing. Our portable flange facing machines resurface corroded or damaged flange sealing surfaces to original specifications without removing flanges from piping systems. We restore flatness within ASME B16.5 tolerances (0.002″ per inch), create proper surface finish for gasket seating (125-250 RMS), and machine new serrations as needed. Combined with our bolt torquing services, we deliver leak-free flange joints restoring equipment to service faster than flange replacement alternatives.

Yes. Cold cutting is not only approved but often required in ADNOC facilities operating under strict HSE protocols. BIJER maintains OSHAD compliance certification and follows ADNOC HSE Code of Practice requirements. Our cold cutting operations comply with ADNOC’s permit-to-work systems, SIMOPS management protocols, and environmental protection standards. We regularly execute cold cutting work in ADNOC facilities across Abu Dhabi, Ruwais, and offshore operations, providing spark-free cutting solutions that meet or exceed ADNOC contractor standards.

Absolutely. BIJER provides 24/7 emergency cold cutting mobilization across Abu Dhabi and UAE. We maintain pre-positioned equipment at major industrial zones (Mussafah, ICAD, Ruwais) enabling rapid response. Emergency calls receive priority dispatch with equipment and crews mobilizing within 2-4 hours. We carry backup machines preventing equipment failure delays. Our emergency services include: leak isolation cutting, failed component removal, emergency tie-in preparation, and structural member cutting for access. Contact our emergency line (+971 54 480 6887) anytime for immediate assistance.