admin 18th April 2025

When a client in the heavy vehicle industry approached Katalyst Engineering with a challenge involving a boom truck’s super-structure, they were seeking more than just a quick fix—they needed a reliable, innovative partner who could re-engineer their equipment for enhanced performance and operational safety. Katalyst Engineering responded with a full-spectrum solution rooted in engineering innovation, mechanical design, and manufacturing excellence.

The Challenge

The client’s boom truck—integral to daily lifting and transport operations—was underperforming due to an outdated and weight-inefficient super-structure. The structure limited payload capacity and introduced stability concerns during operation. This impacted both safety compliance and productivity.

Additionally, the client required:

• Structural reinforcement without increasing overall truck weight
• Integration of modern lifting systems
• Compliance with new regulatory safety standards
• A cost-effective solution that would reduce downtime

This complex combination of design, performance, and compliance presented a formidable challenge—but one perfectly suited for Katalyst Engineering’s multi-disciplinary capabilities in engineering design services.

The Katalyst Approach

Katalyst Engineering began with a comprehensive design audit of the existing boom truck super-structure, using reverse engineering techniques and 3D scanning to gather precise dimensional data. This was followed by a Finite Element Analysis (FEA) to identify stress concentrations and potential failure points under typical and extreme working loads.

Once diagnostics were complete, the team applied their expertise in mechanical design services to reimagine the boom truck’s upper frame. Key improvements included:

• Optimized structural geometry: Lightweight, high-strength design using advanced steel alloys
• Custom fabrication-ready 3D CAD models: Created for precision manufacturing
• Improved load distribution: Modified mounting and support points for stability
• Regulatory compliance built into the design: Adhering to ASME and OSHA guidelines

Throughout the process, Katalyst’s team provided real-time engineering consulting, collaborating closely with the client to ensure design intent met real-world application requirements. Our engineering innovation, design & consulting services allowed flexibility without compromising the structural integrity or project deadlines.

The Outcome

The result was a completely redesigned super-structure that enhanced the boom truck’s capacity, efficiency, and safety:

• 30% reduction in structural weight
• Increased load capacity by 20%
• Lowered center of gravity for better operational stability
• Zero field modifications needed post-manufacturing
• Full compliance with safety and performance regulations

Beyond the technical achievements, the client experienced a significant operational benefit: reduced maintenance costs and improved uptime, directly impacting their bottom line.