Design And Fabrication

Designing Bespoke Equipment

Lifting equipment design services transform complex handling challenges into safe, efficient solutions. At Lifting Gear and Safety, we engineer bespoke lifting beams, spreader bars, frames, padeyes, lift-shaft beams, anchor points, and test fixtures tailored to your load paths, geometry, and site constraints. Our designs are practical and buildable, simplifying operations while protecting people, plant, and structures.

Our Design Process

We take concepts through to detailed design using:

• Precise calculations
• Finite Element Analysis (FEA) where appropriate to verify strength, stiffness, and stability

Materials, welds, and connections are specified to suit service conditions, with clear allowances for off-centre, dynamic, and installation loads. We produce:

• Fabrication drawings
• Bills of materials
• Rigging plans
• Inspection points and WPS/WPQR requirements
• Full traceability for right-first-time fabrication

Compliance Built In

Every design aligns with:

• UK regulations and LOLER duties
• BS/EN standards for lifting accessories (EN 13155)
• Structural steel and welding standards (EN 1090, ISO 9606/15614)
• OEM interface requirements

Where applicable, we prepare:

• Technical file
• Declaration of conformity
• UKCA/CE marking documentation
• Proof-load and NDT plans to validate the finished item before service

Collaborative Delivery

We review your loads, interfaces, and access limits, provide clear calculations and drawings, and support:

• Procurement
• Fabrication oversight
• Site commissioning

If your situation is unusual—restricted headroom, fragile substrates, corrosion exposure, or strict contamination controls—we design around it and propose sensible maintenance and re-certification intervals. The result is a fit-for-purpose lifting solution, backed by evidence, that makes your operation safer and more productive.

Fabricating and Manufacturing Equipment to Solve Unique Challenges

Fabrication services turn engineered designs into robust, compliant lifting equipment ready for service. At Lifting Gear and Safety, we fabricate lifting beams, spreader bars, frames, padeyes, lift-shaft beams, anchor points, and bespoke fixtures in carbon steel, stainless steel, and aluminium—focusing on build quality, traceability, and safe performance.

Precision Fabrication Processes

Our fabrication shops deliver:

• Precision cutting, forming, and machining
• Coded welding to qualified procedures
• WPS/WPQR development and control
• Welders qualified to ISO 9606 with procedures to EN ISO 15614

Materials are sourced with mill certificates, heat numbers, and full traceability. We manage fit-up, preheat, distortion control, and dimensional tolerances so assemblies install cleanly and perform as designed.

Quality Assurance and Inspection

Quality assurance is embedded throughout:

• Visual inspection and dimensional checks
• Non-Destructive Testing (MT/PT/UT where specified)
• Thread and interface verification
• Documented results in an inspection test plan

Surface preparation and coatings follow recognised standards:

• ISO 8501-1 for blast cleanliness
• BS EN ISO 12944 for corrosion protection Options include galvanizing, paint systems, and specialist finishes. For stainless fabrications, we apply clean-area practices, passivation, and contamination control to protect corrosion resistance.

Compliance and Documentation

We fabricate to EN 1090 for structural steelwork where applicable and supply UKCA/CE conformity packs for relevant items. Each item includes:

• Load rating plates
• Serial numbers and marking Before delivery, we can perform proof load tests and functional checks, providing certificates and reports that align with LOLER duties, OEM instructions, and applicable BS/EN/ISO requirements.

Efficient Delivery

You receive:

• Clear fabrication drawings and weld maps
• Material certificates and coating records
• Test reports and inspection documentation Logistics are arranged to suit site access and sequencing. Whether it’s a one-off lifting frame or a repeat production run, our fabrication service gives you fit-for-purpose equipment built to the right standards—with the evidence to back it up.