Starter Service Kit

March 2025 Malik Wadhwa

The Starter Service Kit is a fixed-scope package designed for operators of single high-tonnage gantry cranes who need a baseline technical assessment without committing to a full lifecycle audit. It covers the essential checks required under BIS safety guidelines for overhead steel portals up to 50-tonne capacity.

Each kit includes a visual inspection of main girders, end carriages, and weld joints, followed by ultrasonic thickness readings at ten predetermined locations. The results are compiled into a concise report that flags any section loss beyond 15% of original thickness and recommends immediate or scheduled remediation. No cyclic fatigue testing or finite element analysis is included at this tier, which keeps the turnaround time under five working days.

This product suits facilities that run a single crane on a regular duty cycle and need documented proof of structural condition for internal safety records or insurance compliance. The kit is delivered as a PDF report with annotated photographs and thickness data tables. A follow-up call with the inspecting engineer is included to clarify any findings.

The Starter Service Kit does not replace a full lifecycle audit, but it gives a clear snapshot of current structural health. If the report identifies areas of concern, the client can upgrade to a detailed fatigue analysis or a full lifecycle audit through a separate engagement.

Client feedback on crane audits

What plant engineers and safety officers say about our lifecycle assessments and fatigue testing.

“The cyclic fatigue report flagged a crack in the main girder weld that our internal team missed. We scheduled a repair before the next production cycle — no downtime, no incident.”

Malik Wadhwa — Senior Engineer, Bhilai Steel Works

“After the lifecycle audit we extended inspection intervals on three portal cranes by 18 months. The risk-based plan cut our maintenance spend by 22% without compromising safety.”

Samir Brar — Terminal Operations Manager, Mundra Port

“We had two 50-ton gantry cranes due for replacement. Your assessment showed the remaining life was still safe for another six years. That saved us nearly ₹1.2 crore in capital outlay.”

Ravi Deshmukh — Plant Head, Larsen & Toubro Heavy Engineering

“The ultrasonic thickness mapping on our overhead crane runway beams gave us clear data to prioritise reinforcement. The BIS compliance checklist was a bonus for our next audit.”

Anita Rao — Safety & Compliance Lead, NTPC Korba
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