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 installs machines and plant where space is tight: in existing halls, between running lines, in live data centres and in restricted areas. New builds are the exception, not the rule.

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.

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 weiter.

Omega Mounting Montagefahrzeuge vor dem Einsatz beim Prüfstand-Umbau
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 centre – that is our everyday work, not the exception.

Alle Gewerke in einem Team

Mechanics, mechatronics engineers 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.

Maschinen & Anlagen montieren

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.

Einbringen & Ausbringen

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.

Elektrik & Inbetriebnahme

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.

Stahlbau & Anpassungen

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.

Neubau

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.

Laufender Betrieb

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.
02EINBRINGKONZEPTSpecifying 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.
04INBETRIEBNAHMEAdjusting 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 engineers 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 centre 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 ELSE WE TAKE ON

Industrial assembly

You are here

Heavy loads into finished buildings

Cause rather than symptom

What cannot be bought

Dismantling and clearance

Abbauen, umsetzen, anfahren

Nine industries at a glance

Eigener Bereich, DE & EN

Regelmäßig im Einsatz: Rodgau · Rödermark · Obertshausen · Heusenstamm · Dietzenbach · Seligenstadt · Mühlheim · Offenbach · Dreieich · Babenhausen · Egelsbach · Langen · Neu-Isenburg · Dieburg · Hanau · Maintal · Frankfurt · Darmstadt · Eschborn · Raunheim · Kelsterbach · Rüsselsheim · Weiterstadt · Bad Vilbel · Mainz · Aschaffenburg · Gelnhausen · Stockstadt · Kassel · Marburg · Stadtallendorf · Koblenz

Der Schwerpunkt liegt im Umkreis von rund 40 Kilometern um Rodgau — dort sind unsere Leute abends zu Hause. Für Projekte, die es wert sind, fahren wir bundesweit.

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.

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

Supervisor und Rigger im abgestimmten Einsatz an der Anlage
Repair instead of replace: a refurbished curved rail from an electric overhead conveyor.
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