Tenaris Delivers Industry-First Large-Diameter BlueCoil® Tubing String, Setting New Benchmark for U.S. Shale Operations
In a landmark achievement for the oilfield services sector, Tenaris has successfully delivered a 2 7/8-inch BlueCoil® coiled tubing string to Cudd Pressure Control, establishing a new performance standard for shale operations in the United States. This delivery marks the first time Tenaris has produced its proprietary heat-treated coiled tubing in this larger diameter, tailored specifically to meet the growing demands of horizontal drilling and long-reach well applications in U.S. shale basins.
The monumental 30,250-foot-long tubing string, weighing an unprecedented 192,000 pounds, is now officially the largest and heaviest BlueCoil® string ever manufactured. It will be deployed in Cudd’s operations across the Eagle Ford and Permian Basins, two of the most prolific shale formations in North America.
Addressing the Growing Complexity of Shale Wells
The success of this project underscores Tenaris’s continued commitment to pushing technological boundaries in coiled tubing manufacturing. As unconventional wells in the U.S. become deeper and more complex, operators are increasingly demanding coiled tubing strings that are not only longer, but also more robust and capable of housing larger downhole tools.
Coiled tubing has long been a key component in post-fracturing well operations, particularly for plug milling, cleanouts, and other critical interventions. In these applications, tubing must withstand extreme fatigue and pressure conditions while delivering the necessary flow dynamics for effective well cleanup.
The increase in diameter from standard configurations to 2 7/8 inches offers significant performance advantages. A larger internal diameter allows for improved fluid flow and accommodates higher-capacity tools, enabling faster and more efficient well interventions. However, scaling up diameter also increases the string’s overall weight and complexity, creating significant engineering challenges—challenges Tenaris was uniquely positioned to overcome.
A Collaborative Effort to Engineer the Future
The origins of this record-breaking project date back to August 2024, when Cudd Pressure Control, a leading provider of pressure control and well intervention services, approached Tenaris with an ambitious request: to design and manufacture the largest heat-treated coiled tubing string ever produced in North America.
“This wasn’t just a product order—it was a technical challenge,” explains Brandon Henderson, Sales Manager for Coiled Tubes at Tenaris. “We needed to align teams across engineering, manufacturing, logistics, and supply chain to deliver a solution that met every specification. The scale of this project required a level of cross-functional collaboration that highlights Tenaris’s integrated capabilities.”
Tenaris’s BlueCoil® technology, first introduced in 2015, was the foundation upon which this challenge was tackled. Featuring proprietary heat-treatment and precision manufacturing processes, BlueCoil® offers significantly enhanced fatigue resistance, mechanical strength, and longevity compared to conventional coiled tubing solutions. Over the past decade, more than 1,500 BlueCoil® strings have been deployed globally, solidifying its reputation for quality and durability in the most demanding environments.
The Client’s Perspective: A Game-Changer in the Field
For Cudd Pressure Control, the delivery of the extra-large BlueCoil® string represents a major leap forward in their operational capacity.
“We challenged Tenaris to deliver something that had never been done before, and they delivered,” says Brandon Pugh, Operations Manager at Cudd Pressure Control. “This BlueCoil® string gives us the reach and performance we need for the most demanding shale wells in the U.S. land market. It’s a game changer for our coiled tubing operations.”
According to Pugh, the ability to run longer laterals with greater downhole tool performance is critical to maintaining well productivity and maximizing return on investment in tight oil and gas formations. The longer reach provided by the 30,250-foot string allows Cudd to complete entire laterals without needing to section the job or deploy multiple strings—saving both time and operational costs.
Delivering on a Vision of Partnership and Innovation
Beyond the technical milestone, the project highlights a deep strategic alignment between Tenaris and Cudd Pressure Control. Both companies emphasized the importance of collaboration throughout the planning and execution phases.
“This project reflects the kind of partnership we strive for—where technical excellence and commercial alignment come together to solve real challenges in the field,” says Christopher Schneider, Senior Director of Corporate Business Development at Cudd. “The scale and performance of this BlueCoil® string will open new possibilities for our coiled tubing division. We are very excited to see this string get into service.”
Tenaris took a client-first approach from day one, tailoring its manufacturing process to Cudd’s operational priorities. Each detail—from wall thickness tolerances to fatigue resistance metrics—was engineered to match the unique conditions of shale wells in the Permian and Eagle Ford regions.
Martín Urcola, Vice President of Coiled Tubes at Tenaris, emphasized the value of custom-engineered solutions. “From the initial concept to final delivery, every step was driven by Cudd’s operational requirements. This is a clear example of how we can translate customer needs into engineered solutions,” Urcola noted.
Overcoming the Logistical and Technical Barriers
The scale of the project presented significant logistical hurdles. Manufacturing such a long and heavy string required meticulous planning and coordination among Tenaris’s operations, technology, and logistics departments. The project culminated with production in April 2025 and final delivery in May, just nine months after the initial request.
The company had to optimize its facilities and production lines to handle the 192,000-pound string. Special handling equipment and transport logistics were also arranged to ensure the tubing was delivered safely and on schedule.
“The technical complexity was matched by logistical demands,” added Henderson. “But thanks to the dedication of our teams and the clarity of Cudd’s requirements, we were able to execute seamlessly.”
Setting a New Standard for the Industry
As shale operations continue to evolve toward longer lateral wells, higher temperatures, and more abrasive environments, the need for stronger, longer-lasting, and more efficient coiled tubing strings will only increase.
This project has not only demonstrated the current capabilities of Tenaris’s BlueCoil® technology but has also pushed the boundaries of what is possible in coiled tubing manufacturing.
With the successful delivery of this record-setting string, Tenaris has set a new industry benchmark—one that is likely to influence tubing specifications and well design practices for years to come.
To learn more about Tenaris’s coiled tubing innovations and their impact on modern oilfield operations, visit the company’s official website or explore its BlueCoil® technology portfolio.
