diff --git a/ray-operator/controllers/ray/utils/util.go b/ray-operator/controllers/ray/utils/util.go
index 540162bf9f4..7544cb31387 100644
--- a/ray-operator/controllers/ray/utils/util.go
+++ b/ray-operator/controllers/ray/utils/util.go
@@ -253,6 +253,18 @@ func SafeUint64ToInt64(n uint64) int64 {
 	return int64(n)
 }
 
+// SafeInt64ToInt32 converts int64 to int32, preventing overflow/underflow by
+// bounding the value between [math.MinInt32, math.MaxInt32]
+func SafeInt64ToInt32(n int64) int32 {
+	if n > math.MaxInt32 {
+		return math.MaxInt32
+	}
+	if n < math.MinInt32 {
+		return math.MinInt32
+	}
+	return int32(n)
+}
+
 // GetNamespace return namespace
 func GetNamespace(metaData metav1.ObjectMeta) string {
 	if metaData.Namespace == "" {
@@ -393,15 +405,15 @@ func CalculateMinReplicas(cluster *rayv1.RayCluster) int32 {
 
 // CalculateMaxReplicas calculates max worker replicas at the cluster level
 func CalculateMaxReplicas(cluster *rayv1.RayCluster) int32 {
-	count := int32(0)
+	count := int64(0)
 	for _, nodeGroup := range cluster.Spec.WorkerGroupSpecs {
 		if nodeGroup.Suspend != nil && *nodeGroup.Suspend {
 			continue
 		}
-		count += (*nodeGroup.MaxReplicas * nodeGroup.NumOfHosts)
+		count += int64(*nodeGroup.MaxReplicas) * int64(nodeGroup.NumOfHosts)
 	}
 
-	return count
+	return SafeInt64ToInt32(count)
 }
 
 // CalculateReadyReplicas calculates ready worker replicas at the cluster level
diff --git a/ray-operator/controllers/ray/utils/util_test.go b/ray-operator/controllers/ray/utils/util_test.go
index 8bd37a2e7f8..9a9371acd05 100644
--- a/ray-operator/controllers/ray/utils/util_test.go
+++ b/ray-operator/controllers/ray/utils/util_test.go
@@ -805,6 +805,100 @@ func TestCalculateDesiredReplicas(t *testing.T) {
 	}
 }
 
+func TestCalculateMaxReplicasOverflow(t *testing.T) {
+	tests := []struct {
+		name     string
+		specs    []rayv1.WorkerGroupSpec
+		expected int32
+	}{
+		{
+			name: "Bug reproduction: issue report with replicas=1, minReplicas=3, numOfHosts=4",
+			specs: []rayv1.WorkerGroupSpec{
+				{
+					GroupName:   "workergroup",
+					Replicas:    ptr.To[int32](1),
+					MinReplicas: ptr.To[int32](3),
+					MaxReplicas: ptr.To[int32](2147483647), // Default max int32
+					NumOfHosts:  4,
+				},
+			},
+			expected: 2147483647, // Was -4 before fix, should be capped at max int32
+		},
+		{
+			name: "Single group overflow with default maxReplicas and numOfHosts=4",
+			specs: []rayv1.WorkerGroupSpec{
+				{
+					NumOfHosts:  4,
+					MinReplicas: ptr.To[int32](3),
+					MaxReplicas: ptr.To[int32](2147483647),
+				},
+			},
+			expected: 2147483647, // Should be capped at max int32
+		},
+		{
+			name: "Single group overflow with large values",
+			specs: []rayv1.WorkerGroupSpec{
+				{
+					NumOfHosts:  1000,
+					MinReplicas: ptr.To[int32](1),
+					MaxReplicas: ptr.To[int32](2147483647),
+				},
+			},
+			expected: 2147483647, // Should be capped
+		},
+		{
+			name: "Multiple groups causing overflow when summed",
+			specs: []rayv1.WorkerGroupSpec{
+				{
+					NumOfHosts:  2,
+					MinReplicas: ptr.To[int32](1),
+					MaxReplicas: ptr.To[int32](1500000000),
+				},
+				{
+					NumOfHosts:  1,
+					MinReplicas: ptr.To[int32](1),
+					MaxReplicas: ptr.To[int32](1000000000),
+				},
+			},
+			expected: 2147483647, // 3B + 1B > max int32, should be capped
+		},
+		{
+			name: "No overflow with reasonable values",
+			specs: []rayv1.WorkerGroupSpec{
+				{
+					NumOfHosts:  4,
+					MinReplicas: ptr.To[int32](2),
+					MaxReplicas: ptr.To[int32](100),
+				},
+			},
+			expected: 400, // 100 * 4 = 400, no overflow
+		},
+		{
+			name: "Edge case: exactly at max int32",
+			specs: []rayv1.WorkerGroupSpec{
+				{
+					NumOfHosts:  1,
+					MinReplicas: ptr.To[int32](1),
+					MaxReplicas: ptr.To[int32](2147483647),
+				},
+			},
+			expected: 2147483647, // Exactly at limit
+		},
+	}
+
+	for _, tc := range tests {
+		t.Run(tc.name, func(t *testing.T) {
+			cluster := &rayv1.RayCluster{
+				Spec: rayv1.RayClusterSpec{
+					WorkerGroupSpecs: tc.specs,
+				},
+			}
+			result := CalculateMaxReplicas(cluster)
+			assert.Equal(t, tc.expected, result)
+		})
+	}
+}
+
 func TestUnmarshalRuntimeEnv(t *testing.T) {
 	tests := []struct {
 		name           string