Heavy Steel Fabrication Work

Kothari Chemicals (Engineering Division) provides heavy structural steel fabrication India from its works in Bhilai, Chhattisgarh. We fabricate large structural members and project-specific industrial equipment to customer drawings and specifications for power, steel, mining, cement and infrastructure projects. The works states a maximum single-piece handling capacity of 100 metric tonnes and an annual fabrication capacity of 18,000 to 20,000 metric tonnes.

These are maximum stated capabilities, not slot availability. Production load, crane arrangement, logistics and schedule are confirmed for each package before a date is committed. Request a quote with your drawings and delivery requirements.

What heavy fabrication covers at our works

On this page, heavy fabrication means large, heavy members and assemblies that are cut, fitted, welded, straightened, blasted, coated and dispatched at our Bhilai works. Our scope includes bridge girders, plate and composite girders, technological structures, power-plant steel structures and water-cooled industrial components.

Single-piece handling

The works states single-piece handling of up to 100 metric tonnes. Each lift is reviewed for geometry, centre of gravity, rigging, travel path and resource availability, so a stated capacity does not by itself confirm that a particular member can be lifted. The lifting equipment listed for the works is:

• Multiple 50 T cranes, including a gantry crane in Bay 4
• 40/5 T and 40 T overhead EOT cranes in Bay 3, and a 40/5 T and 20 T overhead EOT crane in Bay 2
• 5 T hoist in the shot-blasting area
• Mobile cranes rated 15 T, 14 T, 12 T and 8 T

The works has multiple 50 T cranes available for heavy lifts.

For the factors behind a heavy enquiry, read our single-piece handling guide.

Equipment for heavy members

• CNC 3-axis drill line with sawing machine
• CNC plasma profile cutting, NC hydraulic shearing and CNC tube bending
• Automatic H-beam cantilever welding and hydraulic straightening machines
• Plate bending and rolling machine, and hydraulic iron worker for shearing and punching
• MIG/MAG, TIG, submerged-arc and stud welding, with welding rectifiers and electrode baking ovens
• Shaper, planer, lathe and end-milling machines for machining
• Aerowheel automatic airless roller-conveyor shot-blasting machine, shot-blast room, paint booth and metalizing equipment

Recent heavy fabrication: BHEL Trichy

In FY 2025-26 we executed a 10,000 MT heavy fabrication programme for BHEL Trichy. The work covered heavy fabricated steel components built to project-specific drawings, inspection requirements and delivery schedules. See our executed project references for other completed work.

Railway and bridge members are covered on the girder bridge fabrication page. Kothari Chemicals holds RDSO registration CBS/G/Reg/Kothari Chemicals for composite girders and other steel plate girders, listed as valid through 31 January 2031.

Quality system and inspection

We hold ISO 9001:2015 certification (QRO certificate no. 305026010110Q). The certificate scope covers heavy building structures, technological structures, bridges and girders. Our quality control guide explains the checks behind each release.

In-house: dimensional, visual and document checks; dye-penetrant testing (DPT); magnetic-particle inspection (MPI); coating adhesion and thickness checks; hydraulic and air-leakage tests.

Outsourced when specified: radiography (RT); ultrasonic testing (UT) and phased-array ultrasonic testing (PAUT); stress relieving; microstructure examination; physical, chemical and mechanical tests. These go to NABL-accredited laboratories and AERB-approved radiography agencies, with qualified NDT personnel.

Inspection extent, acceptance criteria and hold or witness points follow the approved inspection and test plan and the contract. Documentation depends on the contract and can include material certificates, traceability records, WPS/PQR and welder qualifications, dimensional and NDT reports, and a manufacturing record book.

Surface protection

Blasting, painting and metalizing are specified per project. Preparation grade, profile, coating system, dry-film thickness and acceptance criteria come from the project specification. We do not apply one generic coating system to every job. For the approach, read our surface preparation and coating guide.

Sectors we serve

• Power generation and power-plant equipment
• Iron and steel plants, including water-cooled components for high-temperature steel-plant service
• Mining and material handling
• Cement and process plants
• Industrial buildings and heavy structures
• Indian Railways, highway and road bridges

Delivery workflow

Every heavy job follows six stages:

1. Design review. Drawings, specification, bill of materials, quality plan, inspection stages, delivery boundary and schedule are reviewed before production planning starts.
2. Material procurement. Steel and bought-out items are procured to the approved specification, with test certificates and traceability where required.
3. Fabrication. Cutting, bevel preparation, drilling, fit-up, welding, straightening, machining and assembly run under approved shop documents.
4. Surface protection. Specified blasting, painting and metalizing are coordinated with cleanliness and coating controls.
5. Inspection. Visual, dimensional, document and required NDT checks are completed before release.
6. Packing and dispatch. Members are marked, protected and sequenced for loading and delivery.

The full sequence is set out in our delivery workflow post, from design review to dispatch. Long or heavy members also need a route survey, transport permits, confirmed lifting points and site readiness. See the dispatch planning guide.

Lead time. There is no fixed lead time. It depends on engineering release, steel availability, member complexity, tonnage, welding and NDT, coating, inspection hold points, transport permissions and current production load. A committed programme follows review of the complete enquiry.

Design responsibility. Design responsibility is set package by package. We review drawings for manufacturability. Unless the contract states otherwise, Kothari Chemicals is not the engineer of record.

What to send with your enquiry

• Latest drawings and revision register
• Bill of quantities, steel grade and governing codes
• Welding, NDT and coating requirements, and the inspection authority
• Largest member weight and dimensions, including any turning or transfer stages
• Delivery location, dispatch splits and site constraints

Contact our team with these details to request a quote.

Frequently asked questions

What is the maximum single-piece weight you can handle?

The works states single-piece handling of up to 100 metric tonnes. This is a maximum stated capability. Each lift is reviewed for geometry, centre of gravity, rigging, travel path and resource availability before work is committed.

Do you hold RDSO approval?

Kothari Chemicals holds RDSO registration CBS/G/Reg/Kothari Chemicals, covering composite girders and other steel plate girders, listed as valid through 31 January 2031. Verify the registration on the IREPS portal before you award work. The registration covers that girder scope only, not other heavy fabrication.

Do you carry out NDT in-house?

Dye-penetrant testing and magnetic-particle inspection are carried out in-house. Ultrasonic testing, phased-array testing and radiography are arranged through qualified external support when required. Extent, technique, acceptance criteria and reporting follow the approved inspection plan and contract.

Can you deliver heavy members to site?

Yes, subject to member dimensions, weight, loading sequence, route survey, transport permits, lifting points and site readiness. The delivery boundary is agreed before dispatch planning starts.