Steel Under Heavy Cycles

Maritime terminals move thousands of containers per day. Ship-to-shore (STS) cranes, rubber-tyre
gantry (RTG) cranes, reach stackers, empty handlers, spreaders and quay structures absorb enormous
cyclic loads, corrosion and impact. When steel cracks or welds fatigue, the repair must happen on the
terminal—often between vessel calls. The engine driven welder brings field
welding to the berth, keeping the terminal productive.

Typical Terminal Welding Repairs

  • STS crane structures: Boom, girder and trolley rail repairs; fatigue cracks at
    welded details in the main box girder.
  • RTG crane frames: Leg-to-girder joints, gantry drive mounts and structural
    stiffeners.
  • Reach stackers and empty handlers: Frame cracks, mast welds, boom repairs and
    counterweight brackets.
  • Spreader and twist-lock components: Corner castings, flippers and structural
    box repairs on vessel and quay spreaders.
  • Quay and dock steel: Bollards, fender panels, mooring rings and crane rail
    base plates.
  • Yard infrastructure: Gate structures, light towers, fence posts and equipment
    shelters.

Why Engine Power Fits the Terminal

  • No outlets on the quay: The berth and yard have no convenient power; a diesel
    engine driven welder is self-sufficient.
  • High output: 300–500 A for thick crane plate and structural
    members.
  • Auxiliary power: 10–15 kW for grinders, lighting, drills and
    inspection gear during night shifts.
  • Mobile mount: Trailer or truck mount moves between berths, yards and
    repair shops.

Corrosion and Marine Environment

  • Salt exposure: Terminal steel faces chloride corrosion; remove rust, salt and
    contamination before welding.
  • Coating repair: Welding burns through paint and epoxy; plan for coating
    restoration after structural repairs.
  • Material grades: Crane steel is often high-strength (e.g., S355/S420); match
    consumables and procedure to the base material.
  • Preheat: Thick sections and high-strength steel need controlled preheat to avoid
    hydrogen cracking.

Safety on a Working Terminal

  • Hot-work permit: Terminals require a permit for welding; coordinate with the
    shift supervisor and safety officer.
  • Crane lockout: Lock out and tag out the crane before welding on any structural
    part; never weld on a live or moving crane.
  • Fire and spark control: Use blankets and screens; the terminal has fuel,
    hydraulic oil and tyre hazards nearby.
  • Confined space: Crane booms and box girders are confined spaces; follow entry
    procedures and ventilation requirements.
  • Truck and straddle movement: Keep cables and equipment clear of active yard
    traffic lanes.

Inspection and Documentation

  • Crane structural repairs follow the manufacturer’s repair procedure and applicable codes
    (e.g., FEM, EN 13001, CMAA).
  • Use NDT (MT/PT/UT) after welding to verify soundness on critical details.
  • Record the repair, WPS, welder qualification and inspection result in the equipment history.

Conclusion

Maritime terminals and port equipment demand heavy, mobile welding under strict safety and
operational pressure. An engine driven welder with high output and auxiliary power
repairs cranes, handlers and dock steel without moving the part to a shop. Match the procedure to
the steel, control the hot-work permit, and document the repair. Explore our
port and terminal welding equipment for berth-ready machines.

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