Heavy modularization and skidding systems: prefabrication of large modules (process skids, equipment platforms, pipe racks) for off-site construction and expedited installation.

Cutting, Forming and Preparatory Operations

High-capacity plate and section cutting using oxy-fuel, plasma, and CNC laser/oxy-fuel combined systems as appropriate for thickness and material.

Heavy plate forming, bending and rolling capabilities for producing curved shells, saddles and flanged sections.

Machining of large components for precision interfaces and alignment features.

Welding and Joining

Multi-process welding capability (SMAW, GMAW, FCAW, SAW, GTAW) with certified welders qualified to project-specific procedures (WPS, PQRs).

Automated and semi-automated welding lines for long seam welding and repetitive heavy joint production.

Preheat, interpass temperature control, post-weld heat treatment (PWHT) and weld inspection protocols required for thick-section and high-strength alloys.

Assembly, Pre-erection and Modularization

Jigging, fixture design and heavy-duty support frames for accurate assembly of large structures.

Trial fit-up and dimensional verification prior to surface treatment or transportation.

Modular fabrication of skids and units designed for mechanical, piping and electrical integration with reduced field work.

Inspection, Testing and Non-destructive Examination (NDE)

Comprehensive NDE capabilities: visual inspection, magnetic particle, dye penetrant, ultrasonic testing, radiography, and phased array ultrasonic testing for critical joints.

Destructive testing and coupon preparation where required by code and specification.

In-line inspection regimes and hold-point testing integrated with fabrication schedules.

Surface Preparation, Coating and Protective Systems

Surface blasting, profilometry and cleanliness verification.

Application of primers, high-build epoxies, thermally sprayed coatings (zinc/aluminum), and specialized marine and offshore coating systems.

Insulation and cladding works for thermal performance and fire protection as necessary.

Load-out, Transport and Field Services

Engineered load-out planning, heavy lift coordination, and transport logistics for oversized/heavy cargo.

Field erection support: alignment, bolting/tensioning to specified torques, on-site welding, and site-quality verification.

Commissioning assistance and post-installation inspection.

Technical and Operational Capabilities

To execute heavy structural fabrication reliably, Savegen Engineering integrates several capabilities:

Facilities and Equipment: large fabrication bays with heavy-duty cranes (multiple >50–200 t capacity), deep foundations and stable ground for heavy lifting, plate storage and handling systems, CNC plasma/laser cutting suites, large bending rolls and plate formers, and adequately rated welding booths with ventilation and fume extraction.

Skilled Workforce: certified structural welders, fitters, riggers, CNC operators, NDE technicians, structural engineers, and project managers experienced in heavy fabrication disciplines and in working to international codes.

Engineering Systems: CAD/CAM environments that support nesting, CNC output, and clash detection; structural analysis packages for stress, fatigue and stability studies; integrated document control and revision tracking.

Quality Management: documented quality plans, traceability systems, calibration, inspection checkpoints, and formal nonconformance handling and corrective action processes.

Safety and Environmental Management: robust HSE programs, permit-to-work procedures for hot works, confined space and working at height controls, and environmental stewardship for blast media, coatings, and hazardous waste.

Regulatory and Code Compliance

Heavy structural fabrication often intersects with regulated codes and industry standards. Savegen Engineering’s processes are structured to meet or exceed requirements such as:

ASME (for pressure equipment and weld qualifications)

AWS D1.1 for structural welding

API standards for oil & gas structures and subsea components

EN standards for structural steel and coatings in European projects

ISO 9001 for quality management, ISO 14001 for environmental management, and ISO 45001 for occupational health and safety where applicable

The company maintains welding procedure specifications (WPS) and performance qualification records (PQR), and employs NDE methods that comply with client and code requirements. For critical or classified components, Savegen coordinates third-party inspection and certification.

Risk Management and Quality Assurance

Managing the risks inherent to heavy fabrication—material defects, welding discontinuities, dimensional deviations, logistical failures, and safety incidents—requires an integrated assurance approach:

Risk Assessment and Mitigation: project-specific risk registers, engineering reviews, design-for-manufacture assessments, redundancy in critical lift and support systems.

Process Control: standardized work instructions, weld maps, hold points for inspection, and statistical process controls for repeatable operations.

Traceability and Documentation: full material genealogy, welding and NDE records, inspection and test plans (ITPs), and as-built documentation to support lifecycle maintenance.

Third-party Validation: independent inspections and approvals, factory acceptance testing, and certification for pressure-retaining and safety-critical assemblies.

Value Proposition and Competitive Differentiators

Savegen Engineering’s differentiators in heavy structural fabrication can be summarized as follows:

End-to-end capability: integrated engineering, fabrication, testing and field support reduces interface risks and accelerates schedules.

Heavy-lift and handling competence: on-site infrastructure and expertise to manage very large and heavy components safely and efficiently.

Quality-driven execution: disciplined quality systems and certified personnel ensure compliance with stringent industry standards.

Modularization expertise: ability to significantly reduce on-site construction time through preassembled modules and skids.

Material and process versatility: experience with carbon steels, high-strength alloys, corrosion-resistant alloys, and clad/bimetallic solutions for specialized service conditions.

Client-focused project management: transparent reporting, risk mitigation planning, and schedule-driven delivery to meet capital project timelines.

Case Applications and Industry Use-Cases

Industries that benefit from Savegen’s heavy structural fabrication specialization include:

Offshore and Onshore Oil & Gas: topside modules, subsea frames, jackets, platforms, skids and pressure housings where robustness and corrosion resistance are imperative.

Marine and Shipbuilding: hull sections, heavy bulkheads, deck structures, and large propulsion supports requiring precision alignment and fatigue-resistant design.

Power Generation and Heavy Industry: turbine bases, generator frames, boiler structures, and heavy supports where thermal and dynamic loads are significant.

Infrastructure and Bridges: long-span girders, trusses and composite steel-concrete interfaces produced to demanding tolerances and erection constraints.

Mining and Process Plants: heavy frames, crushers, conveyors and structural modules for harsh environmental and load conditions.

Challenges and Mitigation Strategies

Heavy structural fabrication presents challenges that Savegen addresses through proactive strategies:

Logistics and transport constraints: early engagement with transport and lift specialists, modularization to reduce individual component size, and route/permit planning.

Welding and metallurgical issues: rigorous WPS/PQR regimes, preheat and PWHT control, and material selection aligned with environmental and mechanical requirements.

Dimensional control for large assemblies: use of 3D laser scanning and metrology, precision jigs and shimming strategies, and trial assemblies to verify fit.

Skilled labor availability: investment in training, apprenticeship programs, and retention strategies to maintain certified trades competence.

Savegen Engineering’s specialization in heavy structural fabrication brings together heavy industrial facilities, certified personnel, engineering breadth and disciplined quality systems to deliver complex, high-value metal structures for demanding industries. Their end-to-end approach—from detailed engineering and material procurement through precision welding, modular assembly, testing and field erection—reduces project risk, accelerates schedules, and ensures compliance with international standards. By combining technical rigor with project-focused execution and robust safety and quality frameworks, Savegen positions itself as a reliable partner for projects that require the fabrication and delivery of large-scale, safety-critical structural assemblies.