Heavy Industrial Steel Structures

Value engineering in heavy industrial work focuses on load definition and modularization. We challenge conservative load allowances with vendor data, size plate girders with optimized web depth and stiffener spacing, and select between rolled and built-up sections by availability and fabrication effort. Pipe racks are arranged with modular bays that can be pre-assembled. Splitting heavy assemblies at transport-friendly splices avoids oversized shipments while keeping site connections simple.

Typical members include deep plate girders, built-up box and I-sections, heavy columns, equipment support frames, grating platforms, stairs and pipe rack modules. Thick plates may require preheat, controlled heat input and qualified procedures to the AWS D1.1, AS/NZS 1554.1 or EN 1090 execution class specified, often EXC3 for heavily loaded or dynamic elements. Bearing surfaces and machinery support plates are machined where flatness is critical.

Pipe rack modules and complex assemblies are trial-assembled in the shop where specified, then match-marked for reassembly at site. Lifting lugs and temporary transport bracing are designed and fabricated as part of the scope. Platforms, stairs and handrails are detailed for safe maintenance access and fabricated as bolted sections, which allows them to be galvanized separately and installed after the main frame.

Our inspection and test plan reflects the criticality of each element, with hold points on thick plate welding, preheat records and post-weld checks. Mill certificates, including through-thickness and toughness properties where specified, are traced to every piece. Ultrasonic testing is applied to full-penetration and thick plate welds, with magnetic particle testing on fillet welds and radiography where the project specification requires it. Dimensional surveys confirm girder camber, flatness of equipment seats and bolt hole patterns, documented in a complete quality dossier.

Industrial plants often expose steel to C4, C5 or CX environments with chemicals, high humidity, salt or abrasive dust. We select ISO 12944 systems for high durability, typically zinc-rich primers with epoxy and polyurethane coats, or hot-dip galvanizing for platforms, gratings and handrails. Hot surfaces may need heat-resistant coatings, and passive fire protection is coordinated for hydrocarbon fire scenarios where specified. Bolted connection faying surfaces are treated to meet slip requirements.

Heavy assemblies are planned around transport limits from the start. Pipe rack modules, plate girders and large frames are shipped break-bulk or on flat racks with engineered lifting points and sea fastening, while grating, stairs, handrails and bolts are containerized by area. Shipments are sequenced to the plant construction schedule. Each consignment carries packing lists, weight and center of gravity data for heavy pieces, and full export documentation.

We provide erection drawings, lifting point details, weights and centers of gravity for major lifts, and module reassembly instructions. Our engineers give input to method statements and lift plans prepared by the erection contractor, including temporary support of plate girders and sequence of pipe rack installation around existing plant. Technical supervision or advisory support is available when agreed. Erection is performed by the client appointed contractor.