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Materials and Welding Expertise for Crane and Bridge Construction

– where structures are under load

For manufacturers and erectors of cranes, bridges and steel structures: welding consulting, welding qualification and materials consulting – in accordance with EN 1090, EN 1993, FEM and DIN 18800. Assessed for safety-critical applications, documented in conformity with standards.

EN 1090 Steel Construction Welding Qualification Materials Consulting High-Strength Steels Dynamic Loads Bridge Construction Crane Structures

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CHALLENGE

Load-bearing structures have no second chance – material and welding defects have safety- and liability-relevant consequences.

  • An EN 1090 certification is pending – the EXC classification of your component is unclear or disputed.

  • High-strength fine-grain structural steels (S690QL, S960QL) require special preheating and post-weld heat treatment concepts – mistakes are costly.

  • Dynamically loaded weld seams on crane girders or bridges show cracks – the cause and a repair concept are needed.

  • A material specification for a load-bearing structure must be drawn up or reviewed – fatigue, brittle fracture and corrosion must be taken into account.

EXC classification, EN 1090 certification or welding qualification for a load-bearing structure?

We handle the technical preparation and support you all the way to acceptance by the certification body.
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SERVICES

Three core services for manufacturers and erectors of load-bearing structures

01

Welding Consulting for Load-Bearing Structures

Consulting on welding processes, preheating, joint design and heat management – specifically for high-strength fine-grain structural steels, thick-walled load-bearing structures and dynamically loaded constructions.

  • Consulting for S355-S960QL and special grades
  • Preheating and carburisation concepts (DASt)
  • Post-weld heat treatment of thick-walled components
  • Preventing hydrogen-induced cracking
  • Consulting for repair welding on load-bearing structures
S690QL / S960QL DASt Guideline 009
02

Welding Qualification in accordance with EN 1090

Support for welding qualifications for structural steel load-bearing structures – from WPS preparation to acceptance by the certification body. Execution classes EXC 1-4 covered in conformity with standards.

  • Determining the required execution class (EXC)
  • Welding procedure qualification WPS / WPQR (DIN EN ISO 15614)
  • Welder qualifications in accordance with DIN EN ISO 9606
  • Interface with certification bodies (TÜV, DVS-IIW, SLV)
  • EN 1090 initial certification and re-certification
EN 1090-1 EXC 1-4 ISO 3834
03

Materials Consulting for Load-Bearing Structures

Consulting on material selection for steel load-bearing structures, taking into account load cases, notched impact toughness, brittle fracture behaviour, corrosion and economical processability.

  • Material selection in accordance with EN 1993-1-10 (brittle fracture)
  • Notched impact requirements for low temperatures
  • Consulting on Z-grades against lamellar tearing
  • Material certificate assessment (3.1 / 3.2 in accordance with EN 10204)
  • Corrosion and coating consulting for outdoor applications
EN 1993-1-10 Z-Grades EN 10204

STANDARDS EXPERTISE

Steel Construction, Crane & Bridge
EN 1090-1 / EN 1090-2 EN 1993 (Eurocode 3) DIN EN ISO 3834 FEM 1.001 (Crane Structures) DIN EN 13001 DIN EN ISO 15614 DIN EN ISO 9606 DASt Guidelines EXC 1-4 (Execution Classes)

SUBSECTORS

Crane and bridge – related worlds, each with its own logic

CRANE STRUCTURES
Lifting Equipment, Overhead Cranes, Port Cranes, Special Cranes

Crane structures are characterised by cyclic loading and load spectra. Fatigue assessments in accordance with FEM 1.001 and DIN EN 13001 are central requirements – as are welded girder constructions that must withstand thousands of load cycles over decades.

  • Fatigue assessment in accordance with FEM 1.001 and EN 13001
  • Weld seam classes for dynamically loaded girder constructions
  • Inspection concepts for existing cranes
  • Failure analysis of crack formation on crane girders

BRIDGE CONSTRUCTION
Road Bridges, Railway Bridges, Special Structures

Bridge construction follows Eurocode 3 (EN 1993) with particular requirements regarding brittle fracture and fatigue. The DASt guidelines define the limits for high-strength steels. Outdoor weathering, dynamic traffic loads and service lives of 50-100 years make material selection a key decision.

  • Material selection in accordance with EN 1993-1-10 for brittle fracture
  • Fatigue assessments for road and railway bridges
  • DASt guidelines for high-strength steels
  • Corrosion protection concepts for decades of service life

EN 1090 – THE CENTRAL SET OF RULES IN STEEL CONSTRUCTION

EN 1090 is more than a CE mark – it is the entry ticket for every steel construction contract.

EXECUTION CLASSES EXC 1-4
Which EXC class does your component need – and what does that mean?

EN 1090-2 defines four execution classes based on safety and complexity criteria. Correct classification is decisive: under-classification jeopardises approval, over-classification causes unnecessary costs in testing and production. We assess and document in conformity with standards.

EN 1090 INITIAL CERTIFICATION
Initial Certification as a Structural Steel Manufacturer

EN 1090 certification is a prerequisite for placing structural steel load-bearing structures on the market in the EU with a CE mark. We prepare your company: welding supervision in accordance with DIN EN ISO 14731, FPC, welding procedure qualifications, welder qualifications – including audit support.

HIGH-STRENGTH FINE-GRAIN STEELS
S690QL and S960QL – no standard steel

High-strength fine-grain structural steels require strict preheating regimes, controlled heat input and specially selected welding consumables. The DASt Guideline 009 sets the framework – we translate it into concrete welding instructions and production recommendations.

BRITTLE FRACTURE SAFETY
EN 1993-1-10 – the right material grade for load-bearing structures

Brittle fracture is one of the most critical failure mechanisms in steel construction. EN 1993-1-10 links material grade, component thickness, notched impact toughness and service temperature. An incorrect choice can lead to structural failure without warning.

PROJECT REFERENCES (ANONYMISED)

From practice – what we have delivered for steel fabricators and structure manufacturers

CRANE MANUFACTURER
EN 1090 Initial Certification EXC 3 for Overhead Cranes

Support for the complete EN 1090 initial certification for an overhead crane manufacturer – welding supervision, FPC setup, procedure qualifications and welder qualification for S355 and S690QL.

→ Initial certification without additional requirements, CE marking approved

STEEL CONSTRUCTION COMPANY
Materials and Welding Consulting for Railway Bridge

Consulting on material selection in accordance with EN 1993-1-10 for a railway bridge made of S355J2W (weathering structural steel). Welding procedure qualification and heat management concept for thick-walled gusset plates.

→ Structure executed in conformity with standards, service life of 100 years demonstrated

PORT CRANE OPERATOR
Failure Analysis of Crack Formation on a Crane Girder

Forensic analysis after crack formation on the main girder of a port crane after 22 years of operation. Fatigue failure due to insufficient weld quality and notch effects identified.

→ Repair concept developed, continued operation approved for 8 years

COLLABORATION

How a collaboration works

Enquiry

A brief description of your concern – load-bearing structure, material, welding qualification or EN 1090 certification.

Initial Discussion

Within 24 hours: assessment of the scope, clarification of the EXC class and standard requirements.

Consulting & Analysis

Materials consulting, WPS preparation, procedure qualification or failure analysis – on site or in the laboratory.

Report & Acceptance

Complete documentation in conformity with standards – directly usable for the certification body, TÜV or client.

WHY TECHNICAL CENTER

What steel fabricators and structure manufacturers expect from us

EN 1090 Expertise from Practice
We know EN 1090 not just from the manual – we have supported initial certifications from EXC 1 to EXC 4 and know what auditors really look at.
Safety-Critical Thinking
Load-bearing structures rarely fail quietly. We assess with the necessary safety awareness and provide recommendations that hold up in the event of failure.
High-Strength Steels as a Focus
S690QL, S960QL, weathering structural steels – we know the characteristics of the economically most important construction materials in modern steel construction.
Interface with TÜV, SLV and DVS
We speak the language of the certification bodies and ensure that initial certifications and welding qualifications run smoothly.

TYPICAL OCCASIONS

When steel fabricators, crane and bridge manufacturers contact us

  • An EN 1090 initial certification is pending – preparation, FPC setup and audit support needed
  • A welding qualification for a new material (e.g. S690QL) must be developed
  • An existing crane girder or bridge component shows cracks – root cause analysis and repair concept needed
  • The EXC classification of a component is disputed or unclear – assessment in conformity with standards needed
  • Material selection for a new load-bearing structure must be secured in accordance with EN 1993-1-10
  • Clarifying lamellar tearing or Z-grade requirements for thick-walled gusset plates

No urgent need, but questions about EN 1090, EXC classes or high-strength steels?

A non-binding initial discussion is possible at any time.
Request an initial discussion →

FREQUENTLY ASKED QUESTIONS

What steel fabricators and manufacturers want to know before their first enquiry

How is the execution class (EXC) determined for a load-bearing structure?
The execution class according to EN 1090-2 results from three factors: consequence class (CC), service category (static or dynamic) and production category. These give rise to EXC 1 (low requirements) up to EXC 4 (highest requirements). We analyse your component situation, determine the correct EXC and document the classification in conformity with standards – so that you produce neither over- nor under-classified.
Can you support the entire EN 1090 initial certification?
Yes. We handle the complete preparation: setting up the factory production control (FPC), appointing and qualifying the welding supervision (DIN EN ISO 14731), preparing WPS and WPQR, welder qualifications and preparation of the audit documents. During the audit we are on site and ensure smooth communication with the certification body (TÜV, SLV, DVS-IIW).
What special considerations apply when welding high-strength steels such as S690QL and S960QL?
High-strength fine-grain structural steels react very sensitively to heat input and hydrogen absorption. The DASt Guideline 009 provides detailed specifications for preheating temperatures, heat input per unit length and post-weld heat treatment. Mistakes lead to hardening, hydrogen cracks or a drop in strength. We develop your welding instruction in conformity with standards and support the procedure qualification – so that you can realise the greater economic benefit of these steels without technical risk.
What is the difference between FEM 1.001 and EN 13001 for crane structures?
FEM 1.001 is the historically established calculation basis for lifting equipment of the FEM (Fédération Européenne de la Manutention). EN 13001 is the current European standard and increasingly the state of the art. Both work with load spectra and loading groups, but differ in detailed assessments for weld seams and fatigue. We advise on the correct application – depending on the country, client and type of structure.
Can you also assist with damage to existing load-bearing structures?
Yes. Failure analyses on crane structures and bridges are a focus of our work – crack formation, fatigue damage, corrosion damage, weld seam failure. We analyse the cause, assess the remaining load-bearing capacity and develop a repair concept – including support for the repair welding and the subsequent release documentation.
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