Installing GfK tanks for the hybrid burner conversion in Fulda

Project Report: Transport, Lifting, and Securing of Fiberglass-Reinforced Plastic Tanks for a Hybrid Burner Plant in Fulda

The energy crisis and rising gas prices have prompted many industrial companies to rethink their burner systems. A customer of Omega Mounting at its Fulda location also decided to convert its burner systems to Weishaupt hybrid systems in order to reduce its dependence on gas. In addition to replacing the burners, this required the installation of new tanks and silos to supply the burners with the necessary fuel.

Our installation team handled the entire process of installing and connecting these tanks—from navigating the tight logistics on the plant grounds to the final securing of the tanks in the concrete foundation. This project report highlights the key technical considerations involved in installing fiberglass-reinforced plastic (FRP) tanks and answers the questions that decision-makers in industry and plant engineering ask themselves when undertaking such a project.

Occasion

Switch to Hybrid Burners

Components

FRP Tanks/Silos for Fuel Supply

Delivery

Trucks & Flatbed Trailers

Discharge

Telescopic loaders right on the construction site

Lifting equipment

Custom-made lifting crossbeam

Fixation

Heavy-duty anchors in concrete foundations

Why are industrial companies currently switching to hybrid burners?

Independence from Gas Through Hybrid Technology

By switching to a hybrid system, customers will be able to flexibly switch between different energy sources in the future, making them significantly less vulnerable to gas price fluctuations and supply shortages.

However, this requires the right infrastructure: large-capacity tanks that are stable, securely anchored, and properly connected.

Delivery to a confined company premises

The tanks were delivered by truck and flatbed trailer. Since there was limited space on the company grounds in Fulda, precise maneuvering was required: Our technicians guided the vehicles across the grounds so that the tanks could be unloaded directly at the construction site using a telescopic loader —without any detours and without requiring additional space.

Crane Lifting for FRP Tanks

Why a lift plan is essential

Since the tanks are made of glass-fiber-reinforced plastic (GFRP), special care must be taken when lifting them. A custom-made lifting crossbeam ensured that no “diagonal pull” occurred during lifting—as this could tear the glued-on eyelets out of the tank.

To prevent exactly that, every refueling stop with us includes:
a detailed elevatorschedule prepared in advance
Coordinating the lifting points and lifting equipment with the manufacturer
the use of a guide ropethat prevents the tank from swinging uncontrollably during the lift, thereby preventing damage to the tank and surrounding buildings

Crane Safety

The Role of the Crane Guide

With components this large and heavy, the crane operator’s field of vision alone is not sufficient to safely assess every movement. That is why a second person is on site to guide the operation during every lift.

Using radio and hand signals, he maintains constant contact with the crane operator and gives him precise instructions on height and direction—a crucial safety factor in every tank lift.

Foundation & Substrate: The Basis for Stability

To ensure that the fiberglass tanks remain stable and level over the long term, the subgrade is crucial. In Fulda, the tanks were placed on concrete foundations that had been cleaned beforehand. Our installers also laid a protective mat between the tank and the foundation slab.

It evens out minor irregularities in the concrete and protects the tank from localized stress from below.

Fastening with heavy-duty anchors

In the final step, the tanks were securely anchored to the concrete foundation using heavy-duty anchors. This ensures that they remain securely in place even in windy conditions, under the weight of the contents, and during normal operation.

Conclusion: Deploy tanks in Fulda

Experience that matters

From tight delivery conditions to precise crane lifts to final anchoring in the foundation: Installing fiberglass-reinforced plastic (FRP) tanks for hybrid heating systems requires planning, experience, and well-coordinated teams.

With a well-thought-out lifting plan, trained staff, and the right lifting equipment, our installation team safely installed the tanks for the customer in Fulda on schedule—another step toward greater energy independence.

Are you also planning to switch to a hybrid system, or do you need assistance with installing tanks or silos?