Fabrication & Installation Works Workshop to Site — End to End
Professional steel fabrication, precision welding, equipment erection, and commissioning support for hydro power, industrial, and infrastructure projects. High-quality workmanship from workshop to site — IS / AWS / ASME compliant.
What We Fabricate
& Install
ECS provides a complete suite of fabrication and installation services — from raw material procurement to final commissioning at site.
Structural Steel Fabrication
Custom steel structures for hydro & industrial projects
- Hydro-mechanical structural components
- Steel frames, platforms & walkways
- Crane girders & support structures
- Custom structural assemblies
- Heavy-duty plate fabrication
- Stiffened box girder fabrication
- Embedded parts & anchor components
Equipment Fabrication
Hydro mechanical equipment & turbine components
- Turbine casing & spiral casing components
- Penstock, Y-piece & manifold fabrication
- Gate panels & frame fabrication
- Trash rack bar & frame fabrication
- Valve bodies & butterfly disc fabrication
- Mechanical assemblies & sub-assemblies
- Pressure vessel & piping fabrication
Precision Welding & Machining
Multi-process welding & surface finishing
- SMAW (Stick) welding — structural joints
- MIG/GMAW welding — medium fabrication
- TIG/GTAW welding — precision & SS components
- SAW (Submerged Arc) welding — heavy plates
- CNC machining & turning operations
- Surface grinding & finishing
- NDT (radiography, UT, DPT) coordination
Site Installation & Erection
Equipment erection, alignment & grouting
- Hydro turbine installation & erection
- Gate & hoist equipment erection
- Penstock & pipeline site installation
- Equipment alignment & precision leveling
- Grouting, anchor bolt setting & civil interface
- Embedded parts installation & fixing
- On-site technical supervision & inspection
Commissioning & Trial Run
Pre-commissioning, testing & performance validation
- Pre-commissioning checklist preparation & checks
- Mechanical trial run & no-load testing
- Hydraulic system leak testing & flushing
- Load testing & performance validation
- Vibration & noise measurement checks
- System troubleshooting & punch-list clearance
- Commissioning documentation & handover
Surface Treatment & Coatings
Corrosion protection and protective coatings
- Shot blasting (Sa 2.5 grade) & surface prep
- Epoxy primer & intermediate coat application
- Anti-corrosion & anti-rust paint systems
- Underwater epoxy coating for submerged parts
- Rubber lining for penstock / pipe internals
- Coal tar epoxy for water contact surfaces
- DFT (Dry Film Thickness) measurement & QC
Welding Processes
& Technical Capabilities
ECS employs certified welders across multiple welding processes — ensuring the right process for every joint, material, and application.
TIG / GTAW
Precision welding for stainless steel, thin plates & critical joints. High-quality, clean welds.
MIG / GMAW
Semi-automatic welding for medium structural fabrication. High deposition rate, good quality.
SMAW / Stick
Manual arc welding for structural steel joints. Versatile — suitable for site and shop welding.
SAW
Submerged arc welding for heavy plates and long butt welds. High deposition, deep penetration.
🔬 Quality & Inspection
- Qualified welders per IS 7307 / ASME IX
- Welding procedure specifications (WPS / PQR)
- Visual weld inspection (VT) — 100% coverage
- Dye Penetrant Test (DPT) for surface defects
- Ultrasonic Testing (UT) for internal defects
- Radiographic Testing (RT) for critical welds
- Magnetic Particle Testing (MPT) as applicable
- Dimensional checks & joint fit-up inspection
- PWHT (Post Weld Heat Treatment) when required
Our Installation
Process — Step by Step
A disciplined, safety-first installation process that ensures every piece of equipment is erected correctly, on time, and to specification.
Site Readiness Check
Civil readiness, access, crane availability & safety audit before mobilization
Equipment Inspection
Incoming inspection of fabricated equipment, dimensional checks & documentation review
Setting & Alignment
Foundation setting, centreline alignment, precision leveling & anchor bolt fixing
Erection & Assembly
Lifting, erection, bolting, field welding & sub-assembly completion at site
Grouting & Interface
Precision grouting, civil interface completion & embedded part handover
Pre-commissioning
Mechanical checks, trial run, leak test, performance test & punch-list clearance
Quality Control
& Safety Standards
Every fabrication and installation job at ECS follows a documented quality plan — from raw material inspection to final handover.
Material Inspection & Traceability
All raw materials are inspected on receipt with mill test certificates (MTC) verified against IS/project specifications. Material traceability is maintained throughout fabrication.
Inspection & Test Plan (ITP)
A detailed ITP is prepared for every job — defining inspection points, hold points, witness points, and responsible parties for each stage of fabrication and installation.
Non-Destructive Testing (NDT)
NDT methods including VT, DPT, UT, RT, and MPT are deployed as per weld category and project requirements — with qualified NDT personnel and calibrated instruments.
Dimensional & Fit-Up Checks
All fabricated components undergo dimensional verification against approved drawings before dispatch — ensuring correct fit during site installation.
Health, Safety & Environment (HSE)
Strict HSE protocols are followed at workshop and site — PPE compliance, lifting plans, permit-to-work system, fire watch, and toolbox talks before every work shift.
📜 Standards We Follow
Project Types
We Execute
ECS fabrication and installation services are deployed across a wide variety of hydro power and industrial project types.
Hydro Power Plants
Turbine, gate, penstock & hoist installation
High-Head Hydro
Pressure shaft & penstock fabrication
Irrigation Projects
Gate, hoist & canal structure fabrication
Industrial Projects
Structural steel & equipment erection
Mini Hydro Plants
Compact equipment fabrication & installation
Pumped Storage
Reversible unit penstock & gate erection
Pipeline Projects
Steel pipe fabrication & site installation
Rehabilitation Works
Refurbishment & replacement of existing equipment
Why Choose ECS for
Fabrication & Installation?
We bring technical precision, code-compliant workmanship, and disciplined project execution to every fabrication and installation job.
Design-to-Build Capability
ECS can handle both design and fabrication — ensuring drawings are fabrication-friendly and field-proven. No gap between designer and fabricator.
Certified Welders & NDT
Qualified welders (IS 7307 / ASME IX) and NDT-qualified inspectors ensure every weld meets the required quality standard before dispatch.
IS / AWS / ASME Compliant
All fabrication and installation work strictly follows applicable Indian and international codes with traceable documentation.
Site Supervision Included
Our engineers are present on-site during installation and commissioning — ensuring correct erection, alignment, and safety at every step.
Full QC Documentation
Every job comes with complete QC records — ITP, material MTCs, weld inspection records, NDT reports, dimensional checks, and handover docs.
MSME & GeM Registered
Registered with GSTIN, MSME, and GeM — eligible for government tenders, PSU procurement, and public sector projects.
Have a Fabrication or
Installation Requirement?
Share your project scope with ECS — we’ll provide expert workmanship, competitive pricing, and a clear execution plan from workshop to site.