INDUSTRIAL INSTALLATION IN EXISTING FACILITIES

Almost anyone can install on a greenfield site. We come in when the building has long been standing, production is running and no crane can reach inside any more.

20+

years of industrial installation

3

All trades in one team: mechanics, electrics, welding

DE · EN

Project language and documentation

24/7

Fitters on the job – nights and weekends

THE HARD INSTALLATION IS THE ONE IN A FINISHED BUILDING

Omega Mounting montiert Maschinen und Anlagen dort, wo es eng wird: in bestehenden Hallen, zwischen laufenden Linien, in Rechenzentren im Betrieb und in Sperrbereichen. Der Neubau ist die Ausnahme, nicht die Regel. Montage im laufenden Betrieb ist bei uns der Normalfall: abschnittsweise, mit Freigaben und so, dass nebenan weiterproduziert werden kann. Wo wir überall arbeiten, steht auf Industriemontage Hessen and Industriemontage Rhein-Main.

That calls for a different approach. There is no open space for pre-assembly, no mobile crane reaching in from outside, and rarely a time window that can be moved. So we bring our own lifting equipment, including mini cranes, plan the route through the building in advance and install in stages that interrupt operations as little as possible.

Because mechanics, electrics and welding come from the same team here, installation does not stop at the main switch: we adjust sensors and end positions, supervise the test run and hand over a plant that runs – not one that still needs three more appointments with other companies.

For larger industrial installations, planning comes before the first bolt: our office calculates lifting loads, checks routes and load-bearing capacities and prepares a feasibility study if required, before anyone drives to site. On site you then get a team that belongs together: mechanical installation, electrical installation and commissioning by the same industrial fitters who will recognise your plant on the next job.

Looking for an installation company for industrial installation? Omega Mounting is your partner for industrial installation in the Rhine-Main region and across Germany – from the mechanical installation of individual machines to complete installation services. Depending on the job, we send a single fitter or an installation team of mechanics, electricians and welders that builds, connects and hands over a plant in one go. One focus is industrial installation for special-purpose machine builders: the manufacturer builds and commissions, we move in, align and install at the end customer – as an extended workbench, not as temporary labour.

Are you a manufacturer looking for an installation partner?

This page is aimed at companies who want something installed in their own hall. If, on the other hand, you build plant and need someone to install it at your end customer, our page Plant installation at the end customer – continue there.

Omega Mounting service vehicles before the job on the test rig conversion
Test facility of a southern German automotive group: conversion with a fully welded oil pan.

FOUR REASONS WHY COMPANIES CALL US IN

Installation in existing facilities

Finished buildings, live operation, tight routes: from a hydroelectric plant inside an existing building to swapping equipment in a production data center – that is our everyday work, not the exception.

All trades in one team

Mechanics, mechatronics technicians and welders work together. Installation up to the main switch, sensors adjusted, test run supervised – no company waiting on another.

Our own lifting equipment

Mini cranes, spider cranes and lifting gear for finished buildings. We move loads to places neither a mobile crane nor a forklift can reach – along existing routes instead of through torn-open walls.

International and to standard

English as the project language goes without saying, as does documentation to the client’s specification – RAMS, permits, lift plans. Jobs have taken us to Italy, France and Luxembourg, among others.

WHAT WE TAKE ON IN INDUSTRIAL INSTALLATION

From a single machine to a complete line – installed, connected, commissioned and handed over.

Installing machines & plant

Individual machines, production lines, test rigs and special plant: positioned, aligned, linked and commissioned – to the manufacturer’s specification or to your own concept.

Plant conversion in existing facilities

Extending, relocating or converting existing plant while production continues alongside – in stages that halt operations for as short a time as possible.

Moving in & removal

Moving heavy equipment into finished buildings and back out – with mini cranes, spider cranes and our own lifting gear along existing routes. More on this under Lift & Shift.

Electrics & commissioning

Installation up to the main switch, sensors and end positions adjusted, test run supervised. The mains connection and formal acceptance are handled by your in-house electricians or an inspector.

Steel structures & adaptations

Substructures, platforms, brackets and fitting pieces from our own workshop – because in existing plant, almost nothing fits first time. See Steel structures & access platforms.

Documentation to the client’s standard

RAMS, permits, lift plans, photo documentation and acceptance reports – in German or English, as your client requires.

THREE KINDS OF INSTALLATION – AND THEIR RULES

How an installation has to be planned is decided before the first move: by what is already standing and running around the plant.

New build

The open floor

Empty hall, crane reaching in from outside, space for pre-assembly. The simplest case – here it is mainly about keeping to schedule for the other trades.

Conversion in existing facilities

The finished building

No crane reaches inside, no floor space is free, routes are tight. Here it comes down to your own lifting equipment and a move-in concept planned out in advance – our discipline.

Ongoing operations

The plant next door is producing

Work takes place alongside production, above cordoned-off areas or within a shutdown window. Permits, segregation and safeguarding shape the process as much as anything.

HOW AN INSTALLATION IN AN EXISTING FACILITY SUCCEEDS

01SITE WALKChecking the installation location, the move-in route, ceiling heights and load reserves. Whatever will not fit through the door determines the entire process.
02MOVE-IN CONCEPTSpecifying lifting equipment, defining how far to dismantle, agreeing permits and restricted areas, sequencing the steps – in writing, not from memory.
03INSTALLATIONMoving in, positioning, aligning, linking and connecting – mechanics, electrics and welding interlock instead of following one after the other.
04COMMISSIONINGAdjusting sensors and end positions, supervising the test run, handing over documentation and the acceptance report – in German or English.

PROJECTS FROM INDUSTRIAL INSTALLATION

No marketing copy – documented jobs with real findings, all in our job diary.

INDUSTRIAL INSTALLATION: ANSWERED DIRECTLY

Can you move a machine in when a crane can no longer reach the building?

Yes, that is our speciality. We work with our own lifting equipment, including mini and spider cranes, and bring loads in along existing routes – through doors, up ramps, along service corridors. Where necessary we dismantle the machine far enough to fit through and reassemble it at its final position.

Do you handle the electrics and commissioning as well?

Yes. Our mechatronics technicians install up to the main switch, adjust sensors and end positions and supervise the test run. The mains connection and formal acceptance are usually handled by your in-house electricians or an inspector – we hand over a running plant, not a building site.

Do you work abroad as well?

Yes. Jobs have taken us to Italy, France and Luxembourg, among others. English as the project language goes without saying for us, as does documentation to the client’s standard – we know RAMS, permits and lift plans from the data center business.

Can production continue during installation?

Often yes. We work alongside the line, above cordoned-off areas and on isolated sections. Where a genuine shutdown is needed, we schedule it for a weekend or a shift break and prepare everything so that only the installation itself happens within that window.

What if something does not fit in the existing plant?

That is more the rule than the exception – older installations rarely match the drawing. We manufacture substructures, brackets, fitting pieces and reinforcements in our workshop in Rodgau, often while the installation is still under way. That is why a discrepancy stays a work step for us instead of becoming a stoppage.

How large can the projects be?

From a single machine to a complete line. For scale: we have installed generators up to 3 MW, assembled 320 CRAH units into a continuous fan wall and lifted 54-tonne containerised standby power units. For larger undertakings we scale the team accordingly.

What does an industrial fitter actually do at your company – which trades are behind the job?

"Industrial fitter" is not an apprenticeship trade but an activity. Behind our industrial fitters are trained metalworkers, electricians and mechatronics technicians, a state-certified technician and colleagues with production experience, plus installation helpers for the hands-on work. It is exactly this mix that makes mechanical installation, electrical installation and commissioning from a single source possible – in a breakdown, three or four trades stand in front of the plant together, instead of yet another contractor having to be ordered first.

Do you also take on pre-assembly and assembly automation?

Yes. On request we pre-assemble modules in our own workshop so that on site they only need to be set and aligned – this noticeably shortens downtime. In assembly automation we build, relocate or convert automated systems, handling equipment and robot cells; our mechatronics technicians are confident with control technology. Programming new control systems is not our business – for that we work with the plant manufacturer.

Do I get the same people on every job?

Yes, and for us that is the single most important point. Our core crew of 15 employees looks after its clients on a permanent basis. Whoever installed your plant once will recognise it on the next job – you never explain anything twice. That is the difference from industrial installations handled through changing agency workers.

And if more people are needed at short notice?

Then we scale up through established partner companies. In addition to the core crew we can mobilise around 20 subcontractor fitters, within a few days. They are well-rehearsed crews we have worked with for years – not agency workers recruited at short notice. They are led by our own supervisors so that working methods and safety standards stay the same.

How quickly are you there when a plant is at a standstill?

We are an early-riser company: the first crew is on site from five in the morning, the office can be reached from six. Because our fitters live around Rodgau and know the roads in the Rhine-Main region, we are usually on site the same day within the area. We have the same clear agreement with all clients: if there is a fire at your place, we come – and in return you understand if a plannable appointment has to be moved once because there is a fire somewhere else. We catch up on postponed work, at the weekend if necessary.

WHAT ELSE WE TAKE ON

Industrial installation

You are here

Heavy loads into finished buildings

Cause rather than symptom

What cannot be bought

Dismantling and clearance

Dismantle, relocate, restart

Nine industries at a glance

Dedicated division, DE & EN

Where we install

Our workshop is located in Rodgau, between Frankfurt and Aschaffenburg. From there we reach half the Rhine-Main region before rush-hour traffic builds up — we leave at six.

For the following towns we have dedicated pages with the industrial estates, travel times and the jobs we have actually carried out there.

Rhine-Main and Lower Main

Day-trip sites without overnight stays, fixed departure in the morning.

Further afield

Projects with overnight stays — where we have worked for regular clients for years.

Your town is not listed? That does not mean we will not come. Give us a call: 06106 / 239 25 88

IS AN INSTALLATION COMING UP?

Tell us briefly what needs installing and how it has to get there – we will come back with a realistic assessment.

Would you like an overview for your files first? All services in compact form, ready to pass on: our brochure as a PDF download.

We install throughout the Rhine-Main region and beyond – as far as the Odenwald: Industrial installation in Höchst im Odenwald.

100% free of charge and without obligation · Omega Mounting GmbH, Rodgau near Frankfurt

Supervisor and rigger working in coordination on the unit
Repair instead of replace: a refurbished curved rail from an electric overhead conveyor.

Is a complete site move coming up? Then the route is via plant and site relocation: machinery relocation, warehouse technology and high-bay racking, clearance and reassembly – with the same crew from dismantling to trial run.

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