Moving a press weighing over 100 tons is not a simple one-time relocation of a machine. In practice, it is a technical relocation—that is, the entire process of moving production equipment from its original location to a new one. It begins with surveying the route, assessing the floor, and preparing the machine. It continues with handling, transport, and positioning. It is not complete until the machine is connected and inspected.
Why Moving Over 100 Tons Is a Whole Different Ballgame
A heavy press simply stands in its place. The floor supports it, the connections work, and the operators know it inside out. But as soon as the decision to move it is made, problems arise that routine operations don’t address. That’s why, when it comes to heavy presses, we don’t just talk about moving them—we’re talking about relocating the technology. It’s not just a matter of getting the machine from point A to point B. It’s necessary to verify whether it can be safely disconnected, moved, re-installed, reconnected, and handed over so that it can continue to function.
With machines weighing over 100 tons, issues arise that can change the procedure, cost, and timeline. Can the floor support the handling? Can the equipment be brought into the hall? Can the machine be transported in one piece, or will disassembly be necessary? And will transport on public roads be required? The answer always depends on the specific machine, hall, and route. Therefore, the exact procedure cannot be determined from a desk without a technical inspection.
What Changes When the Weight Exceeds a Certain Limit
The 100-ton limit is not just a rough estimate in the quote. When transporting on public roads, it has a direct impact on the planning of the entire relocation. This involves obtaining a special road use permit, route approval, transport conditions, technical support, and, depending on the specific decision, coordination with the Czech Police.
Permits cannot be processed at the last minute. Obtaining one usually involves documenting the route, assessing passability, verifying road restrictions, and coordinating the process with other entities. Therefore, the transport date cannot be moved shortly before execution without affecting the entire schedule. Inside the hall, a different logic applies, but the principle is the same. The heavier the load, the more critical every meter of the route and every point through which the handling equipment passes becomes.
What Needs to Be Resolved Before Setting a Date
Most complications during the relocation of a heavy press do not arise during the move itself. They arise earlier, when the date is set before the route, floor conditions, equipment, and related trades are determined. Before scheduling the move, the following must be clear:
- which route the machine will take out of the hall and into its new location,
- whether the handling route is passable,
- what the floor load capacity is at both locations,
- whether the press can be transported as a single unit or whether disassembly will be necessary,
- what needs to be disconnected, drained, or secured,
- who will arrange for electricians, hydraulics technicians, service personnel, and inspection technicians.
Who Is Typically Responsible for What During a Press Relocation
When relocating a heavy press, it is necessary to determine right from the start who is responsible for which part of the preparation. The company handling the move cannot replace a structural engineer, an inspection technician, or the customer’s in-house maintenance staff.
| Area | Who Usually Handles It | Why It Is Important |
|---|---|---|
| Machine Technical Documentation | Customer | Without the weight, dimensions, center of gravity, and connection diagram, it is impossible to accurately plan the handling process. |
| Surveying the Route in the Hall | Relocation Company | This verifies clearance, door height, passage width, obstacles, and space for equipment. |
| Floor load-bearing capacity assessment | Structural engineer provided by the customer | Handling equipment can create a higher local load than the stationary press itself. |
| Disconnecting power | Electrician / customer maintenance | The machine must be safely shut down and disconnected before handling. |
| Hydraulics, pneumatics, cooling | Maintenance / specialized technician | It is necessary to disconnect utilities, drain any fluids if necessary, and secure the circuits. |
| Dismantling of machine parts | Machine service / relocation company as agreed | The route, weight, manufacturer’s instructions, and subsequent adjustment are decisive. |
| Handling and installation | Relocation company | Handles lifting, moving, loading, unloading, and positioning of the machine. |
| Permit for oversized transport | Carrier / specialized logistics provider | If transport takes place on public roads, the route and transport conditions must be approved. |
| Inspection after reconnection | Inspection technician | After reconnection, it must be verified that the equipment meets the requirements for safe operation. |
The Floor, Route, and Center of Gravity: Three Factors That Can Throw the Entire Plan Off Course
The floor is often the most underestimated part of the preparation. A press can stand in one place for years, and the floor supports it without issue because the static load is distributed over a larger area. However, during handling, the weight is concentrated at the contact points of the rollers, undercarriages, or lifting equipment. Localized loads can thus be significantly higher. An industrial floor can be designed for heavy loads, but the specific load-bearing capacity always depends on a structural assessment of the given structure. If the construction documentation does not contain the necessary data, this assessment must be conducted prior to relocation.
The route is not just about the width of passageways and the height of doors. It also addresses the strength of channels and crossings, and most importantly, whether the handling equipment can even reach the starting position. Sometimes it is necessary to remove doors, temporarily widen an opening, or relocate connections that obstruct the route.
Furthermore, the press’s center of gravity may not coincide with its geometric center. Heavier moving parts, hydraulic units, or protrusions on one side of the machine can shift it off-center. When lifting, this affects the placement of slings, lifting points, and the entire handling process.
As a whole, or in parts?
Moving the press as a whole is faster, simpler, and cheaper. However, this is only possible if the route, floor, and transport parameters allow it. The decision on whether the machine will be moved as a whole or must be disassembled depends mainly on:
- the machine’s dimensions,
- weight,
- the width and height of passageways,
- the load-bearing capacity of the floor and transport route,
- and the manufacturer’s or service technician’s instructions.
Transport, Positioning, and Post-Transport Inspection
Loading is not just a matter of pulling up a trailer. The heavy press must be secured so that the weight distribution matches the axle load capacity of the vehicle combination and so that the machine is safely anchored to prevent movement. If the transport takes place on public roads, permits, the route, and transport conditions must be arranged. The route must take into account bridge load capacities, clearance heights, road widths, and any traffic restrictions. The transport of very heavy machinery is therefore often scheduled outside of rush hour or during nighttime hours.
Relocation does not end once the machine is in place at its new location. The press must be leveled, anchored according to the documentation, connected to utilities, and subsequently inspected. Only then does it make sense to begin adjustment and test operation. What is not typically an automatic part of relocation: machine servicing, repair of worn parts, inspection of electrical equipment, and commissioning of the technological process. It is therefore advisable to have the scope of responsibilities clearly defined in the contract.
How to Minimize Production Downtime
The best way to minimize production downtime during a relocation is through thorough preparation, not on-site improvisation. Proper timing is key—for example, a weekend, a public holiday, or a natural gap in the order schedule. However, it is important to recognize that preparatory steps require a certain amount of time. Permits, technical assessments, coordination of trades, and workplace preparation cannot be safely handled at the last minute.
Relocation in Phases
If operations cannot be shut down all at once, a phased relocation may be the solution. Part of the preparation is done in advance, some work takes place outside of operating hours, and the shutdown itself is reduced to the absolute minimum. This is more demanding from an organizational standpoint, but for busy operations, it can significantly reduce the impact of the relocation on production.
Common mistakes during preparation
Most problems arise when relocation planning starts with a deadline rather than a technical assessment. Typical mistakes include:
- the deadline is set before the route and floor conditions are clear,
- searching for the machine’s documentation only after the order has been placed,
- coordination with electricians, maintenance staff, and inspection technicians is addressed too late,
- the workspace for the technicians’ arrival is not prepared,
- it is unclear who is responsible for structural engineering, permits, or inspections.
Frequently Asked Questions (FAQ):
What information do I need to provide to the relocation company in order to receive an accurate quote?
The basics are the machine’s dimensions and weight—ideally from the manufacturer’s documentation—photos of the origin and destination locations, including access routes, the height and width of passageways, a description of the flooring along the route and at the destination, and information on what needs to be disconnected before the move.
How long does it take to move a press weighing over 100 tons?
The actual handling can take one day. The entire project, from the technical inspection through preparation, transport, and installation, typically takes several days to weeks, depending on the scope. The duration depends mainly on whether disassembly is necessary, how complex the route is, whether a transport permit is required, and how prepared the destination site is.
When is it necessary to disassemble the press?
The press is usually disassembled when it would not fit through the route as a whole, would not fit under a gate or underpass, would exceed the load capacity of a section of the route, or if moving it as a whole would require unreasonably complex structural modifications. The decision should always be based on a technical inspection, the machine’s documentation, and the recommendations of the manufacturer or service technician.