Heavy lifts that other contractors won't underwrite
Erecting a 60-metre, 350-ton column inside an operating refinery is not a crane job — it is an engineering exercise. Ground bearing capacity, outrigger spreads, tail-crane choreography, weather windows, exclusion zones, PTW interfaces with the operating unit, and a millimetre-accurate landing on the foundation bolts: each one has to be planned, signed and underwritten before the boom comes out. HAIL has done it more than 40 times — including 350+ ton lifts at 60-metre elevation — without a single dropped load incident.
What we erect
Distillation & fractionation columns
Tall multi-section columns for refinery and petrochemical units, including absorbers, splitters and strippers.
Reactors & regenerators
Catalytic and hydroprocessing reactors, FCC regenerators and ammonia converters.
Heat exchangers & air-fins
Bundle pulling, re-tubing, exchanger erection and air-fin cooler installation.
Drums & vessels
Knock-out drums, reflux drums, separators and accumulators — both vertical and horizontal.
Pipe rack modules
Pre-fabricated pipe rack and equipment platform modules — modular construction for refinery revamps.
Flare stacks & chimneys
Self-supporting and guyed flare stacks; lift-and-stand erection or step-up jacking.
Owned crane fleet
| Capacity | Type | Typical use |
|---|---|---|
| 200 MT | Crawler / hydraulic | Heavy column lifts, sphere erection, reactor placement |
| 100 MT | Crawler / hydraulic | Mid-weight columns, exchangers, modules |
| 50 MT | Hydraulic | Drums, vessels, structural steel |
| 20 MT | Hydraulic | General assembly, piping, structural |
For super-heavy lifts beyond owned capacity, we work with India's leading heavy-lift crane suppliers under pre-arranged tie-ups, so the schedule never slips waiting for a crane.
Engineered lift planning
- Ground bearing capacity (GBC) survey and outrigger pad design.
- Crane configuration drawings, boom-and-jib geometry, capacity-vs-radius checks.
- Rigging gear take-off — slings, shackles, spreader bars certified to load.
- 3D lift studies for tandem and tail-crane operations.
- Method statement, JSA, PTW interfaces and HSE briefing pack.
- Weather window and wind-speed cut-offs.
Reference projects
- IOCL Barauni Refinery — Coker-B Revamp: heavy equipment erection, multi-discipline EPCC inside live unit.
- IOCL Gujarat Refinery — N-Butanol Project for Thyssenkrupp Industrial Solutions: equipment fabrication and erection inside a live refinery.
- 40+ critical heavy equipment erections across refinery, fertiliser and chemical industries — leadership-led.
Why HAIL for Mechanical Erection & Industrial Construction
- Owned crane fleet — no rental risk, no schedule slip.
- Engineered lift studies before every critical lift.
- Refinery PTW-trained crew with zero dropped-load incidents.
- Same contractor that fabricates the column also erects it — eliminates fit-up surprises.
- RINA Consulting consortium for independent rigging and design verification when required.
Frequently asked questions
What is the heaviest lift HAIL has executed?
350+ tons at 60-metre height inside a live refinery. Each critical lift carries an engineered lift study, GBC assessment and rigging plan.
Does HAIL own its cranes?
Yes — 200 MT, 100 MT, 50 MT and 20 MT. For super-heavy lifts we have tie-ups with India's leading suppliers.
What equipment do you erect?
Columns, reactors, regenerators, exchangers, drums, modules, flare stacks and structural steel.
Can you work inside a running refinery?
Yes — under PTW with full HSSE and operating-unit interface; we have done it at IOCL Barauni and IOCL Gujarat.
Do you issue lift studies and method statements?
Yes — ground bearing, rigging gear, 3D crane studies, JSA, weather criteria and HSE briefing pack are part of every critical lift.