Structural cracks in metal components are more than surface-level problems — they’re warning signs of stress, fatigue, or failure that can compromise the safety and efficiency of your operations. As a facility manager or business owner, recognizing these issues early can prevent costly downtime and major repairs.
At Pegasus Mobile Welding, we offer on-site welding solutions across Commerce City, CO and nearby areas. In this guide, we break down where and why cracks occur, what to look for, and when it’s time to call a professional.
High-Stress Areas Where Structural Cracks Commonly Appear
Tip: Many metal cracks start small and go unnoticed until something fails. Inspect the following areas during routine maintenance.
1. Loading Docks and Dock Equipment
Why it matters: Constant vehicle impact and forklift movement introduce metal fatigue over time.
- Cracks near dock leveler hinges
- Separation at plate edges or base welds
- Rust lines near brackets and pivot points
Related service: Warehouse Dock Welding & Maintenance
2. Structural Steel Framework
Look for cracks at:
- Beam-to-column welds
- Roof support gussets
- Areas with rust streaks or paint bubbling
3. Stair Rails, Platforms, and Ladders
- Handrail base welds
- Platform edge joints
- Anchor bolts showing signs of metal fatigue
4. Trailers, Hitch Assemblies, and Equipment Mounts
- Welds near hitches or drawbars
- Cracks in axle supports or trailer ramps
- Frame flexing under dynamic load
5. Equipment Support Brackets and Machine Bases
- Cracks in welded brackets or mounting plates
- Weld heat zones breaking down
- Equipment that shifts or rattles in operation
6. Custom Metal Frames and Fabrications
- Corners of fabricated housings
- Stress near hinges or access doors
- Heat discoloration around older welds
7. Repaired Welds That Re-Crack
- Cracks forming again near old welds
- Weak or porous weld beads
- Visible movement or vibration at the site
How to Know When Welding Is Required
- The crack exceeds 1 inch in length
- Rust is visible within or around the crack
- The structure moves or flexes under stress
- Cracks grow or reappear after repair
- The item is part of a safety system
What Pegasus Mobile Welding Can Do
We provide on-site structural crack inspections, preparation, and mobile welding services using certified techniques. Our team is equipped to repair or reinforce damaged areas while minimizing downtime and ensuring long-term performance.
Preventative Measures
- Perform routine visual inspections
- Avoid overloading structural metal
- Reinforce brackets in high-vibration areas
- Apply corrosion-resistant coatings
See also: Custom Steel Fabrication Services
Conclusion
Cracks in metal structures don’t develop overnight. They’re signs of mechanical stress, poor welds, or environmental wear. Catching these cracks early helps prevent equipment failure, compliance issues, and safety hazards.
Pegasus Mobile Welding is ready to inspect and repair structural cracks anywhere in Commerce City or the greater Denver area. Don’t wait until damage spreads — contact us today for expert on-site welding solutions.