When moving in huge machines into production halls, obstacles can occur that do not appear to be obstacles at first glance. To ensure that this runs smoothly, experts are required who have a precise overview of the travel routes, door openings and possible height differences.

In the industrial sector in particular, factory halls are large, but door openings are often insufficient for the dimensions of the machines to be moved in. Transporting machines to higher floors or moving them in via the roof can also be a challenge. And even after being brought into a factory building, further obstacles can arise on the way to the actual final place. Machines often have to be placed on special foundations or in oil pans, where height differences have to be taken into account. This requires specialised equipment and the right expertise.

Before we start: the project review.

Before starting any machine removal or installation, the project must be prepared in detail. This is where experts such as SCHOLPP and the customer’s specialised staff should work together. The possible implementation options are examined, taking into account a whole range of factors such as

  • Requirements at the installation site
  • Time frame
  • Budget
  • Safety requirements
  • Technical specifications of the transported goods (dimensions, weight, load absorption, sensitivity)
  • Simulation of transportation routes
  • Visualising the move in and assembly processes
  • Industry-specific requirements (e.g. clean rooms)
  • Commercial conditions (e.g. liability and insurance conditions)

Once all the requirements have been recorded, the planning for the project begins. Project managers, assembly planners and designers get together and review the processes and interfaces together. The result is a comprehensive and detailed planning in which everyone involved knows exactly when and how to act.

The first major obstacle: the door height

Good planning can be identified very quickly by whether the height of the entrance gate is still an obstacle after unloading or whether a solution has already been found.

Checking the dimensions of the entrance in relation to the transported goods also includes checking the floor load. Normally, the systems are delivered by lorry: even if the door opening allows the transport vehicle to enter directly, it is not yet certain whether the floor can withstand the weight of the lorry and the goods being transported. These issues must also be clarified in advance and alternative solutions considered if the standard solutions cannot be realised. Possible concepts could be: the removal of gates or walls, the temporary dismantling of media lines in the transport or work areas or the preparate of storage areas for the equipment used that meet the load-bearing capacity requirements.

Planning always leads directly to the next step: How will the transported goods moved to the final position? This is decisive on which way of move in is used. Because if the route between the door and the final position is blocked due to insurmountable obstacles, even the cleverest solution for overcoming restricted door heights has its limits.  If this is the case, the SCHOLPP experts plan alternative solutions right from the start, which allow the machine to be brought in via the upper floor or roof using a crane, for example.

The alternative: installation via the roof or upper floor

Just as when using ground-level door openings, it is important to check the dimensions beforehand and plan the lift carefully when moving machines in via roof openings. A crane is then usually used. There are various crane types available, which are selected depending on the requirements of the goods to be lifted, the unloading location and the production hall height. Ideally, the crane can be used to load the goods directly through the intended roof opening. However, this requires intervention in the building structure and sometimes also the statics of the hall. This is not without risk.

However, there are also more satisfying alternatives for move in via the upper floor. One solution could be to remove façade elements from the building to create an opening for the machines. The lifting goods are moved on a platform (‘flying carpet’), which is lifted to the opening in the façade by a crane.

This way of move in is particularly useful for smaller numbers of machines. For larger quantities and over a longer project period, it is advisable to permanently install a gantry in the immediate vicinity of the hall. This acts as a temporary machine lift and can be customised to the conditions on site by combining various lifting equipement components. Prerequisite is sufficient space in this area for the installation of the gantry. With a clever setup, transport routes can also be kept free for factory traffic.

On the moving in route: Obstacles in the factory hall

Further building or production-related restrictions can also occur within the factory halls on the transport route to the final machine location. These include the spatial conditions, additional doors, ceilings that are too low, media supply lines that run deep (ventilation ducts or pipes) or differences in level within the production areas (e.g. steps, thresholds or ramps) or sometimes nothing, such as a pit. However, the load-bearing capacity of the floor along the entire transport route can also become an obstacle. SCHOLPP’s planners check the following points, among others:

  • Dimensions on the transport route
  • Floor load
  • Floor quality (e.g. suitability for trolleys or air cushion technology for vibration-free transport)
  • Radii (manoeuvring areas and curves)
  • Working area of mobile cranes

SCHOLPP relies on tested special equipment for these particular requirements. This includes transport rollers, lifting gantries or heavy-duty trolleys. In the case of limited floor load-bearing capacities, e.g. due to cavities or duct covers, the loads can be distributed using steel plates, for example, or the ground can be secured using supports.

The ultimate challenge: To the final machine place

At SCHOLPP, a successful move in is completed with precise positioning and alignment at the desired location in the workshop. Here, too, there are often height differences to overcome, for example if the machine has to be placed on foundations or platforms or in pits or oil pans. Mobile or indoor cranes or lifting gantries are used to turn or tilt the machine if necessary. SCHOLPP uses damping or levelling elements for precise positioning.

Normally, machines are set down at ground level. However, if height differences occur here too, special solutions are required, such as

  • Lowering into a pit: in metalworking and heavy industry.
  • Positioning above an oil pan: for environmental protection.
  • Lifting onto foundations: Placing components on special platforms or mezzanines in energy technology, the process industry or plant engineering.

After being set down, the systems sometimes have to be aligned down to a hundredth of a millimetre in order to meet even the most precise specifications. Once everything is perfectly in place, the team takes care of the media connections and prepares for commissioning. Thanks to decades of experience and maximum precision in planning and realisation, SCHOLPP is in a position to guarantee that even the most complicated move ins are carried out professionally and on time.

Read our article 12 tips for your machine transport to find out what else you should bear in mind when moving machines.