Crane Fabrication & EOT Crane Structures in India

A crane girder failure does not just stop production. Depending on the type of crane and the load it is carrying, it can kill people. That is why crane girder fabrication demands more care — more thorough inspection, tighter dimensional tolerances, more rigorous documentation — than most structural steel work. At Sun Corporation, crane fabrication and EOT crane structures are a core workshop specialisation, and crane girder work is one component of that package. We have been fabricating EOT crane runway beams, under-slung crane track systems, and complete crane bay structural steel for industrial clients across India for 25+ years.

crane girder fabrication India EOT crane runway beam workshop IS 807:2006 Sun Corporation Hyderabad — Crane girder fabrication at Sun Corporation’s Hyderabad workshop — Runway beam materials, dimensions and inspection requirements follow the approved project drawings.

This page covers the structural steel supporting industrial cranes: runway beams, columns, brackets and associated bracing. A fabrication enquiry should include the crane supplier’s wheel loads and layout, approved structural drawings, rail and connection details, material grades, coating specification, inspection requirements and delivery dates. Confirm crane machinery, electrics, rails, installation and testing responsibilities separately. Send crane-support steel drawings for quotation.

What a crane girder actually is and why it matters

A crane girder — also called a gantry girder or runway beam — is the steel beam that runs along the top of the crane bay at high level, supporting the crane rail on which the end carriages of the overhead travelling crane run. The crane wheel loads transfer through the rail into the top flange of the girder, and from there through the girder to the crane columns and into the foundations. Every time the crane accelerates, brakes, or swings a load, the girder absorbs dynamic forces in addition to the static wheel load. Over the life of a factory — which might be 40 or 50 years — a heavily used crane girder goes through millions of load cycles. Fatigue is a real design consideration, not a theoretical one.

IS 807:2006 — the Indian standard for the design, erection, and testing of cranes and hoists — recognises the fatigue issue by classifying cranes by duty class and specifying different design requirements for different duty levels. There is no such thing as a generic crane girder that fits any application.

How crane fabrication is executed at Sun Corporation

Crane girder fabrication starts with the crane layout drawing from the crane supplier and the structural design from the structural engineer. Problems arise when the fabricator starts work before these two documents are reconciled. At Sun Corporation, we request both documents before preparing shop drawings. If there are discrepancies — wheel loads on the structural drawing that do not match the crane supplier’s updated data sheet, clearance requirements that conflict with the proposed girder depth — we raise them before fabrication begins, not during.

Web and flange plate preparation

The web and flange plates for crane girder fabrication are cut on our CNC plasma table, which gives us edge straightness and squareness that manual cutting cannot match. For heavy crane girders — runway beams for cranes above 30 MT capacity — the flange plates are typically 25 to 50mm thick and the web plates 16 to 20mm thick. We check flatness, dimensional accuracy, and mill test certificate traceability for every plate before it enters production.

Assembly, welding and camber setting

Assemble web, flange and stiffener plates to the approved fabrication drawings and applicable welding procedure. Stiffener positions, weld sizes, joint preparation, camber and inspection extent follow the design and project specification. Camber is not a universal L/1000 requirement for every runway beam; confirm the specified value and survey method before fabrication.

crane girder fabrication heavy plate sections India UT MPI weld inspection IS 807 Sun Corporation — Crane girder fabrication — heavy plate sections with UT inspection of full-penetration welds and MPI of fillet welds. All camber records included in quality dossier.

NDT and inspection

Agree weld examination methods, extent, acceptance criteria and personnel qualifications in the inspection plan. UT, magnetic particle or penetrant testing must suit the joint, material and specified requirements. Record the required dimensional checks, including girder length, depth, bolt positions, specified camber and rail-seat geometry, before dispatch.

Crane columns and bracket seats

The crane girder does not sit on the same column as the main building frame in most industrial shed designs. It sits on a separate crane column with a bracket welded to it at the level of the crane girder bottom flange. Crane column fabrication is part of the complete crane girder fabrication package at Sun Corporation. We fabricate the crane columns — typically heavy UC sections or welded box columns for large cranes — with the welded bracket seats, base plates, and anchor bolt templates. All bracket-to-column connections are inspected by MPI.

Under-slung cranes and monorail track systems

Under-slung cranes and monorail hoists — where the hoist and crab run on the bottom flange of the track beam — are widely used in Indian industry for lighter loads up to 5 MT. Sun Corporation fabricates under-slung crane track beams — straight sections, curved sections to specified radii, and all associated support steelwork including hangers, brackets, and end stops. We supply the complete under-slung system as a numbered kit with installation instructions.

What determines a crane-support steel quotation

Steelwork: approved member sizes, material grades, piece weights and quantities.
Crane interface: wheel loads, duty information, rail details, support spacing and connection requirements.
Fabrication and inspection: joint details, specified camber, weld examination and dimensional tolerances.
Supply scope: coating, transport limits, delivery sequence and any site erection.

IS 807 and the standards that govern crane girder fabrication in India

IS 807:2006 governs crane girder fabrication and crane supporting structure design in India — duty class classification, fatigue load spectrum, minimum camber, deflection limit under crane wheel load, and tolerance requirements for rail alignment. IS 800:2007 governs the structural design of the crane supporting structure. IS 875 Part 2 specifies imposed loads including crane wheel loads. IS 1893 applies in seismic zones for the crane supporting structure design.

Enquiries for crane fabrication and EOT structures

For a crane-support steel quotation, send the crane layout, wheel-load data, approved girder and support drawings, material grades, quantities, coating system, inspection requirements and site location. Include the required delivery sequence and identify whether transport or erection is included. Feasibility, production availability and quotation timing are confirmed after review.

Contact Sun Corporation for crane girder fabrication. Also see: Heavy steel fabrication | Industrial shed fabrication | Structural steel Hyderabad