Heavy Duty Metal Fabrication Solutions
Industrial-grade heavy component manufacturing — integrating thick-plate laser cutting, large-scale CNC gantry machining, structural welding, and stress-relieving heat treatment for heavy machinery and equipment.
Heavy Structural Fabrication & Large Component Manufacturing
Manufacturing heavy-duty metal components for mining, construction machinery, energy systems, and heavy industrial equipment requires far more than basic sheet metal tools. It demands massive crane capacity, thick plate cutting systems, high-rigidity CNC machining centers, and licensed structural welders capable of deep-penetration multi-pass welds.
Conwhole provides comprehensive Heavy Duty Metal Fabrication services engineered for structural integrity, extreme load endurance, and harsh environmental performance. From heavy steel frame weldments and crane booms to thick mounting bases and large gear housings, we manage the complete fabrication cycle under strict quality management.
Key Takeaways
- Heavy Plate Processing: High-power fiber laser cutting in-house and plasma cutting via partner for steel plates up to 50 mm thick with bevel cutting options.
- Large-Scale CNC Machining: Large gantry CNC milling and floor-type boring machines for weldments up to 4000 × 2000 × 1200 mm.
- Structural Welding: Multi-pass TIG/MIG welding with NDT non-destructive testing (UT, MT, PT).
- Thermal Stress Relieving: Post-weld heat treatment (PWHT) furnace processing to prevent structural warping and residual stress failure.
Heavy Steel Plate Cutting & Beveling
We process thick carbon steel, high-strength alloy, and stainless steel plates using in-house high-wattage fiber laser cutting and partner-managed plasma cutting systems equipped with multi-axis beveling heads for weld joint preparation.
| Parameter / Capability | Technical Specification |
|---|---|
| Cutting Thickness | Carbon Steel: 0.5–50 mm; Stainless Steel: 0.5–30 mm; Aluminum: 0.5–25 mm |
| Beveling Angles | Automated CNC beveling (V, Y, K, X grooves) up to 45° for thick plate welding |
| Max Sheet Size | Large bed capacity up to 6000 × 2500 mm |
| Material Grades | Q235, Q355B/D, S355JR, Hardox 400/500 wear plate, SS304/316L heavy plate |
Large-Scale CNC Gantry Machining & Boring
Our heavy-duty gantry CNC machining centers and horizontal floor-type boring machines process massive welded structures and thick steel castings, achieving precise mounting surfaces and pin-bore alignments.
| Parameter / Capability | Technical Specification |
|---|---|
| Travel Envelopes | Gantry CNC Milling up to 4000 × 2000 × 1200 mm; Floor Boring up to 3000 × 1500 mm |
| Machining Accuracy | Positional tolerance ±0.02 mm; Bore coaxiality within 0.015 mm over 1000 mm span |
| Lifting Capacity | Integrated overhead cranes up to 10 Metric Tons lifting capacity |
| Secondary Features | Deep-hole drilling, face milling, heavy thread tapping, precision counterboring |
Multi-Pass Structural Welding & NDT
Heavy structural integrity relies on deep-penetration welding. Our experienced welding engineers utilize heavy-duty MIG/MAG, FCAW flux-cored arc welding, and submerged arc welding (SAW) on Siegmund 3D fixture tables.
| Parameter / Capability | Technical Specification |
|---|---|
| Welder Qualification | Licensed welders (government-issued operation licenses) |
| NDT Inspection | Ultrasonic Testing (UT), Magnetic Particle Testing (MT), Dye Penetrant (PT), Visual (VT) |
| Stress Control | Pre-heat induction controls, multi-pass interpass temperature monitoring, Siegmund 3D tables |
| Heavy Assemblies | Heavy excavator arms, chassis frames, crane turntables, industrial furnace bases |
Stress Relieving, Surface Protection & Logistics
To ensure long-term structural dimensional stability, we conduct post-weld stress relieving followed by shot blasting, heavy-duty anti-corrosion coating, and specialized export packaging for heavy machinery shipment.
| Parameter / Capability | Technical Specification |
|---|---|
| Stress Relieving | Vibrational stress relief (VSR) & Post-Weld Heat Treatment (PWHT) furnace anneal |
| Surface Preparation | SA 2.5 shot blasting to remove mill scale, rust, and weld slag |
| Heavy Coating | Epoxy primer + Polyurethane topcoat (up to 300+ µm DFT), Hot-Dip Galvanizing |
| Export Packaging | Reinforced heavy timber cradles, anti-rust VCI film wrapping, container lashing |
Representative Heavy Duty Components & Applications
| Category | Representative Custom Components | Heavy Processes | Primary Materials |
|---|---|---|---|
| Mining & Earthmoving | Excavator boom arms, loader buckets, frame chassis, track frames | Heavy plate laser, robotic FCAW, gantry milling | High-Strength Q355D, Hardox 400 |
| Construction & Cranes | Crane outriggers, turntable bases, lattice mast sections | Plasma beveling via partner, SAW welding, UT testing | Structural Steel Q355B, S355JR |
| Energy & Power | Wind turbine flanges, transformer tanks, generator mounting skids | Heavy bending, stress relief heat treatment | Heavy Carbon Steel, Stainless Steel 304 |
| Industrial Machinery | Hydraulic press frames, heavy shear beds, crusher housings | Heavy plate cutting, deep-hole boring, PWHT | Thick Steel Plate Q235/Q355, Cast Steel |
| Marine & Offshore | Offshore deck winches, towing brackets, heavy mooring bollards | Heavy TIG/MIG welding, shot blast, epoxy coat | Stainless Steel 316L, Marine Carbon Steel |
Why Choose Conwhole for Heavy Duty Components?
Massive Heavy Fabrication Capacity
Equipped with 10-ton overhead cranes, 50mm thick plate laser cutting systems, and 4-meter gantry CNC mills, we comfortably process massive structural weldments in-house.
Experienced Structural Welders & NDT Testing
Our welders are licensed, experienced professionals. All heavy weldments undergo non-destructive testing (UT, MT, PT) to ensure 100% weld joint integrity under extreme stress.
Post-Weld Stress Relieving & Machining
We perform PWHT furnace annealing to eliminate residual welding stresses, followed by post-weld CNC gantry machining to guarantee perfectly flat, warp-free reference mounting faces.
Heavy-Duty Coating & Global Export Logistics
We apply industrial SA 2.5 shot blasting and heavy epoxy/polyurethane coatings, packaged in reinforced export timber cradles for safe container shipping worldwide.
Frequently Asked Questions — Heavy Duty Components
Q1: What steel plate thicknesses and dimensions can Conwhole process for heavy components?
We cut carbon steel plates up to 50 mm thick, stainless steel up to 30 mm, and aluminum up to 25 mm using high-power fiber laser and plasma systems. Our maximum single plate bed capacity is 6000 × 2500 mm.
Q2: What non-destructive testing (NDT) methods do you provide for heavy weldments?
We conduct Ultrasonic Testing (UT) for internal weld defect detection, Magnetic Particle Testing (MT) for surface/near-surface cracks, Liquid Penetrant Testing (PT), and 100% Visual Inspection (VT) per structural welding standards.
Q3: How do you guarantee flat mounting surfaces on large welded frames?
After structural welding, we perform Post-Weld Heat Treatment (PWHT) or vibrational stress relief (VSR) to eliminate thermal distortion. The structure is then loaded onto our 4-meter gantry CNC milling center to machine reference faces and pin bores in a single setup.
Q4: What is your maximum lifting and crane handling capacity?
Our heavy fabrication bays are equipped with integrated overhead bridge cranes capable of handling individual weldments and assemblies up to 10 Metric Tons per single piece.
Q5: What anti-corrosion coating options are available for heavy outdoor machinery?
Following SA 2.5 shot blasting, we apply multi-layer epoxy primer and polyurethane topcoats engineered for salt spray corrosion resistance (ASTM B117 1000+ hours). Hot-dip galvanizing and specialized marine paint systems are also available.
Q6: Do you provide Material Test Reports (MTR) for heavy structural steel plates?
Yes. All steel plates (Q355D, Hardox, SS316L) are directly sourced from tier-1 steel mills. We archive and supply full Mill Test Reports (MTR / EN 10204 3.1) showing chemical analysis and mechanical impact test data with every delivery.
Q7: How are heavy structural weldments protected during international sea freight?
Components are wrapped in anti-rust VCI film, secured with custom heavy timber cradles, and lashed into open-top or flat-rack shipping containers using high-tensile steel strapping and turnbuckles to prevent transit movement.
Q8: How do I request a quote for heavy-duty custom fabrication?
Submit your 3D CAD models (.STEP, .IGES) and 2D structural drawings (.PDF, .DWG) specifying material grades and NDT requirements. Our heavy engineering team will review the drawings and provide a formal quote within 24 hours.