Industrial Structures
Heavy structural steel for plants, mills, conveyor gantries, and crane beams — designed, fabricated, and erected in-house with full surface protection and project-specific engineering.
Industrial-Grade Fabrication for Process Plants & Heavy Industry
- Tekla Structures detailing at LOD 350+
- Crane gantries up to 120 T capacity
- Conveyor galleries spanning up to 30 m
- High-durability coating systems for corrosive environments
- Precision blast-clean + DFT logging per member
- QR-tagged modular assemblies for site speed
- Own erection crew HIAB cranes & boom lifts
- Heat-number traceability for every plate
Prayag Fab Solutions delivers end-to-end structural steel fabrication and erection for refineries, petrochemical complexes, power plants, cement works, and general process industries. Every project is detailed using Tekla Structures at LOD 350+, so the steel that leaves our shop fits first time on site — reducing costly re-work and schedule overruns.
What We Build
Our industrial structures scope covers the full primary and secondary steelwork envelope of a process plant:
- Main-frame structures — multi-tier pipe-rack bents, column-and-beam frames for equipment modules, and structural sub-frames for rotating machinery.
- Crane gantries & EOT runway girders — designed for capacities from 5 T to 120 T with pre-cambered plate girders and precision crane-rail welding.
- Conveyor galleries & trestle bridges — truss or plate-girder galleries spanning up to 30 m, complete with walkway grating, handrails and weather cladding.
- Equipment platforms & mezzanines — secondary steel on existing structures, including stairs, ladders, open-grid flooring, and kick-plates.
- Monorail beams & jib cranes — fabricated from UB/UC sections with precision-drilled end-plates for bolt-up accuracy.
Surface Protection
Coating systems are selected to project environment: from a simple 2-coat epoxy primer + polyurethane topcoat for mild exposure to a full zinc-rich primer + intermediate epoxy + fluoropolymer topcoat system for marine/offshore environments. All blast-cleaning is carried out to industry-standard cleanliness before painting, and DFT is measured and logged per member.
Transport & Erection
Large assemblies are sub-divided into transportable modules (max 12 m × 3 m × 3 m for standard road transport), match-drilled in the shop, and tagged with QR codes for rapid site identification. Our 30-strong erection crew equipped with HIAB cranes, boom lifts, and fall-arrest systems handles complete structural erection, survey, plumbing, grouting, and joint-inspection sign-off.
Industrial Structures — What We Deliver
Every capability is supported by in-house equipment, qualified procedures, and documented quality records.
Process Plant Steel
We model every structural member in Tekla Structures at LOD 350, generating fabrication drawings, CNC NC files, bolt lists, and erection sequences directly from the 3-D model. Clash detection is run before any steel is cut, eliminating surprises during site erection. Our detailing team coordinates with process, piping, and civil disciplines so that pipe-rack nozzle flanges, anchor-bolt templates, and equipment access openings are all resolved on paper — not on site.
Crane Gantries
Structural steel and plate material is procured from SAIL, Tata Steel, and JSW Steel with full material traceability for every heat. Bolts, nuts, and washers are sourced to high-strength Grade 8.8 specification. Incoming material is verified for section dimensions, surface condition, and mechanical properties before acceptance — non-conformances are rejected at the gate, not discovered during fabrication.
Conveyor Galleries
Our 8,000 sq ft CNC-equipped fabrication shop runs beam drilling lines, plasma-profile cutters, and submerged-arc welding sets. Members are fabricated to tight tolerances, with primary welds executed by experienced, qualified welders and inspected by our in-house weld inspector. All weld joints are marked with welder ID stamps for full traceability. Where required, radiographic (RT) or ultrasonic (UT) testing is carried out before dispatch.
Built-Up Sections
We fabricate built-up plate girders for long-span crane runway beams, portal frames, and heavy equipment support frames where rolled sections are insufficient. Flanges are flame-cut and machined to flatness; web-to-flange fillet welds are continuous double-pass; and pre-cambering is achieved by controlled heat-line application. Finished girders are documented with camber measurement records and load-test reports where specified.
Secondary Platforms
Secondary steelwork — access platforms, stair towers, walkways, and maintenance catwalks — is designed for 4 kN/m² live load with open-bar grating or chequered plate to suit the environment. We integrate safety handrails to standard height requirements, self-closing gates at stair heads, and safety netting attachment points. Secondary steel is pre-assembled in the shop in the largest practical modules for minimum site assembly time.
Surface Protection
Coating specifications are agreed at project kick-off and applied under controlled shop conditions. Systems range from zinc phosphate primer + alkyd topcoat for mild exposure to zinc-rich epoxy primer + glass-flake intermediate + polysiloxane topcoat for marine and offshore environments. All surfaces are precision blast-cleaned, DFT is measured with calibrated gauges at every member, and a full coating inspection report is issued with each dispatch.
A Four-Stage Engineering Discipline
Design & Detailing
Our structural engineer reviews the project brief and applicable design requirements, agrees member sizes and connection philosophy with the client, then produces Tekla Structures 3-D model, fabrication drawings, and a full material take-off (MTO). Client and third-party checker sign off GA drawings before fabrication commences.
Material Procurement
MTO is released to approved vendors for competitive quotation. Material is ordered with full heat-traceability. On delivery, our QC team verifies section dimensions, surface condition, and chemical/mechanical properties against supplier documentation — non-conforming material is rejected and replaced at vendor cost.
Shop Fabrication
Steel is cut, drilled, and fitted to fabrication drawing tolerances. Welds are executed by experienced qualified welders, inspected by our in-house weld inspector, and RT/UT-tested where specified. Members receive precision blast-cleaning and the agreed coating system. Each piece is tagged with a QR code and loaded for dispatch in erection sequence.
Erection & Handover
Our erection crew mobilises with HIAB cranes, mobile towers, and boom lifts. Survey control (total-station setting-out) is established before the first column is lifted. Bolted connections are tensioned to snug-tight or full-pretension as per the drawing. On completion, a dimensional survey and joint inspection report is issued, and the structure is handed over with an as-built drawing set.
Recent Industrial Structures Projects
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Delivered 480 tons of structural steel two weeks ahead of schedule, fully NDT-certified. Zero rework on site.
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