Dismantling and Lowering of a 16-Ton Rotary Mixer in Hannover

Meeting the Challenge of Specialized Industrial Equipment Relocation

When it comes to industrial machinery relocation, few tasks are as demanding as the dismantling and vertical transport of massive rotary equipment. Recently, our team at OKSEL completed one of technically challenging projects: the dismantling and multi-story lowering of a 16-ton rotary mixer in Hannover, Germany. This complex operation showcased our expertise in specialized machinery relocation, requiring precise planning, custom solutions, and flawless execution in a confined industrial environment.

Industrial relocation projects involving rotary mixers present unique challenges due to their size, weight, and specialized connections. In this comprehensive case study, we'll take you through our systematic approach to this demanding project, highlighting each critical phase from initial assessment and electrical disconnection to the precision lowering operation and final preparation for transport. Whether you're planning a similar project or simply interested in the technical intricacies of industrial equipment relocation, this guide demonstrates the expertise required for successful heavy machinery dismantling and transport.

The Hannover Rotary Mixer Relocation Challenge

Before diving into the specifics of our approach, let's outline what made this particular industrial equipment relocation so challenging:

• Equipment Specifications: A 16-ton industrial rotary mixer with complex electrical and mechanical connections

• Location Challenges: The equipment was positioned on the third floor of an industrial facility in Hannover

• Structural Limitations: Confined spaces and architectural constraints requiring wall removal and floor modification

• Precision Requirements: Need for controlled vertical lowering through multiple stories without equipment damage

• Safety Considerations: Ensuring worker safety while handling extremely heavy equipment in a confined space

Each of these factors required specialized knowledge in industrial machinery dismantling and transport, making this project a perfect demonstration of our comprehensive relocation capabilities.

1. Initial Assessment and Electrical Disconnection

Comprehensive Site Evaluation

Every successful machinery relocation begins with thorough preparation. Our team of industrial relocation specialists arrived at the Hannover facility to perform a detailed assessment of both the rotary mixer and its surrounding environment. This crucial first step allowed us to identify potential challenges, develop safety protocols, and create a customized dismantling strategy.

The initial evaluation revealed several critical factors that would influence our approach:

• The mixer's position within the facility limited traditional removal options

• Building structure would require modification to facilitate equipment extraction

• Electrical systems needed careful documentation for future reinstallation

• Accumulated material within the mixer required removal before transport

Professional Electrical Disconnection and Documentation

The first hands-on step in our machinery dismantling process involved the careful disconnection of all electrical systems. This critical phase required experienced electrical technicians who understood industrial equipment connections.

Our team methodically:

1. Implemented proper lockout/tagout procedures to ensure safety

2. Disconnected all power supplies to the rotary mixer

3. Created comprehensive electrical documentation, including:

• Detailed wiring diagrams

• Control system specifications

• Connection points and terminal identifications

• Sensor and instrumentation details

This meticulous electrical documentation proved essential for the eventual reconnection of the machinery at its new location. While many industrial machinery movers might overlook this critical step, our experience has shown that thorough electrical documentation prevents costly delays during reinstallation.

2. Equipment Preparation and Cleaning

Thorough Cleaning of Accumulated Materials

Industrial rotary mixers typically accumulate significant amounts of material during their operation, and this Hannover mixer was no exception. Before proceeding with the dismantling process, our team needed to thoroughly clean the equipment to:

1. Reduce overall weight for safer handling

2. Prevent contamination during transport

3. Allow clear access to connection points and mounting brackets

4. Enable proper inspection of all components

The cleaning process involved specialized industrial cleaning techniques appropriate for the specific materials handled by this mixer. Our team used proper PPE and containment methods to ensure environmental compliance throughout the cleaning process.

Preparation for Structural Modifications

With the rotary mixer cleaned and fully documented, we began preparations for the structural modifications needed to extract the equipment. This phase required close collaboration between our industrial relocation experts and structural specialists to ensure building integrity would be maintained throughout the process.

The confined space of the third-floor location meant traditional removal methods were impossible. After careful evaluation, we determined that:

1. A section of wall would need to be temporarily removed to create access

2. Floor reinforcement would be required to support equipment during positioning

3. A precisely calculated opening in the floor would need to be created for vertical lowering

Each of these modifications required careful planning and execution to maintain building structural integrity while creating sufficient access for the 16-ton mixer.

3. Structural Modifications for Equipment Extraction

Strategic Wall Removal for Access

Based on our detailed site assessment, we identified the optimal wall section for temporary removal. This process involved:

1. Careful inspection to identify any electrical, plumbing, or structural elements within the wall

2. Installation of temporary support structures to maintain building integrity

3. Precise cutting and removal of the wall section using specialized tools

4. Creation of reinforced edges to prevent structural damage during equipment movement

This strategic wall removal created the necessary access route for initially repositioning the rotary mixer, allowing our team to begin the critical process of preparing for vertical transport.

Floor Modification and Support

With access established through the wall removal, our next challenge involved creating a precisely calculated opening in the floor for the vertical lowering operation. This complex process required:

1. Structural analysis to identify load-bearing elements

2. Installation of reinforcement frames to maintain floor integrity

3. Precise cutting of the floor opening to the exact dimensions needed

4. Creation of a secure perimeter around the opening with safety barriers

Throughout this process, our industrial machinery movers maintained constant communication with facility managers and structural engineers to ensure all modifications met safety standards and building code requirements.

4. Equipment Suspension and Preparation for Lowering

Custom Rigging System Implementation

With the structural modifications complete, we proceeded to the critical task of suspending the 16-ton rotary mixer in preparation for lowering. This phase required specialized rigging expertise and equipment designed specifically for heavy industrial machinery relocation.

Our team implemented a custom-designed rigging system that included:

1. Multiple connection points distributed to evenly balance the mixer's 16-ton weight

2. Reinforced lifting straps rated for industrial equipment with appropriate safety factors

3. Custom-designed attachment fixtures that protected the mixer's critical components

4. Vibration dampening elements to prevent damage during movement

The implementation of this rigging system represented one of the most technically demanding aspects of the entire relocation project, requiring precision engineering and experienced execution.

Equipment Suspension and Stability Testing

With the rigging system in place, our team carefully transferred the rotary mixer's weight to the suspension system. This delicate process involved:

1. Gradual weight transfer from mounting points to rigging system

2. Continuous monitoring of load distribution across all connection points

3. Real-time adjustments to ensure perfect balance and stability

4. Verification testing to confirm the system could safely support the full 16-ton load

Once suspended, the rotary mixer was carefully positioned above the prepared floor opening, ready for the precision lowering operation to begin.

5. Precision Vertical Lowering Operation

Chain Hoist System Configuration

The heart of this industrial equipment relocation project was the vertical lowering operation that would transport the 16-ton mixer down three floors. For this critical task, we deployed a sophisticated chain hoist system with a combined lifting capacity of 20 tons - providing a essential safety margin for the 16-ton load.

Our chain hoist configuration included:

1. Multiple synchronized chain hoists positioned for optimal load distribution

2. Redundant safety systems to prevent uncontrolled movement

3. Communication systems allowing operators on different floors to coordinate precisely

The setup of this specialized vertical transport system required experienced industrial relocation technicians with specific expertise in heavy equipment vertical movement.

Controlled Three-Story Descent

With all systems in place, we began the carefully controlled descent of the rotary mixer. This operation represented the most critical phase of the entire relocation project, requiring:

1. Extremely precise control of descent speed

2. Continuous monitoring of equipment position to prevent contact with building structures

3. Real-time adjustment of hoist tensions to maintain perfect equipment orientation

4. Coordination between team members positioned at different levels of the building

The entire lowering operation took several hours, with our team maintaining constant vigilance throughout the process. This methodical approach ensured the rotary mixer reached ground level without any damage or safety incidents - a testament to our expertise in industrial machinery relocation.

6. Ground-Level Transfer and Transport Preparation

Telescopic Loader Transfer

Once the rotary mixer reached ground level, we needed to transfer it to our specialized transport equipment. For this phase, we utilized a high-capacity telescopic loader with a 21-ton lift capacity - providing ample capability for the 16-ton mixer.

The transfer process involved:

1. Careful positioning of the telescopic loader beneath the suspended mixer

2. Gradual weight transfer from the chain hoist system to the loader

3. Secure attachment to prevent any shifting during ground transport

4. Final detachment of rigging equipment once the mixer was fully supported

This specialized telescopic loader provided the maneuverability needed to navigate the confined spaces of the facility while safely supporting the massive weight of the industrial mixer.

Professional Export Packing and Transport Preparation

With the rotary mixer successfully lowered and transferred to our transport equipment, the final phase involved preparing it for safe transport to its destination. Our industrial machinery movers implemented comprehensive export packing procedures, including:

1. Application of protective coverings for sensitive components

2. Installation of shock-absorbing materials to prevent transit damage

3. Secure anchoring to prevent movement during transport

4. Comprehensive labeling and documentation for transport compliance

This meticulous preparation ensured the rotary mixer would arrive at its destination in the same condition as when it left the Hannover facility, ready for reinstallation.

Technical Expertise: Specialized Equipment for Heavy Industrial Relocation

Chain Hoists: Precision Control for Heavy Loads

The success of this project relied heavily on our specialized chain hoist system. These industrial-grade hoists offered:

• Combined lifting capacity of 20 tons (providing a safety margin for the 16-ton mixer)

• Precise control allowing millimeter-accurate positioning

• Synchronized operation for perfectly level movement

• Redundant safety features preventing equipment failure

Our technicians' expertise with these specialized hoists allowed them to execute the complex lowering operation with confidence and precision, maintaining perfect control throughout the three-story descent.

Telescopic Loader: Power and Maneuverability

Once at ground level, our 21-ton capacity telescopic loader provided the perfect combination of lifting power and maneuverability. This specialized equipment offered:

• 21-ton lifting capacity (exceeding the mixer's 16-ton weight)

• Precise hydraulic controls for exact positioning

• All-terrain capability for navigating industrial environments

• Compact design relative to its lifting capacity

The availability of this specialized equipment, combined with our operators' expertise, ensured the ground-level handling and transport preparation proceeded smoothly and safely.

Overcoming Challenges: Problem-Solving in Industrial Relocation

Confined Space Navigation

One of the most significant challenges in this Hannover project was navigating the confined industrial spaces. Our team overcame these limitations through:

1. Detailed pre-project mapping and measurement

2. Creative problem-solving in developing custom extraction routes

3. Strategic building modifications minimizing structural impact

4. Specialized equipment selected for space-constrained operation

These approaches exemplify the problem-solving mentality that distinguishes expert industrial machinery relocation specialists from general equipment movers.

Weight Management and Load Distribution

The 16-ton weight of the rotary mixer presented significant challenges for both the building structure and our equipment. We addressed these through:

1. Comprehensive structural analysis before any weight transfer

2. Multiple attachment points distributing load evenly

3. Continuous monitoring throughout the relocation process

4. Selection of equipment with appropriate safety margins

This attention to weight management and load distribution ensured both worker safety and equipment protection throughout the project.

Conclusion: Successful Completion of a Complex Industrial Relocation

The successful dismantling and lowering of the 16-ton rotary mixer in Hannover demonstrates the level of expertise and specialized equipment required for complex industrial machinery relocation. Through methodical planning, custom solutions, and flawless execution, our team completed this challenging project safely and efficiently.

Key factors contributing to this success included:

1. Comprehensive pre-project assessment and planning

2. Specialized equipment selection appropriate for the specific challenges

3. Experienced technicians with expertise in heavy industrial relocation

4. Methodical approach prioritizing safety and equipment protection

This project highlights why specialized knowledge is essential for complex industrial equipment relocation, particularly when dealing with heavy rotary machinery in confined spaces.

Ready for Your Next Industrial Relocation Challenge?

Whether you're planning the relocation of a single piece of specialized equipment or an entire production line, our team brings the same level of expertise and methodical approach demonstrated in this Hannover project. With specialized equipment, experienced technicians, and proven processes, we ensure your industrial machinery arrives safely at its destination, ready for reinstallation.

Contact us today to discuss your specific industrial relocation needs and discover how our specialized approach can benefit your next project.

Learn More About Our Industrial Relocation Expertise

If you found this case study informative, we invite you to explore our other successful industrial relocation projects. Check out our recent project on "Dismantling, Relocation and Assembly of the Production Line" to see another example of our comprehensive industrial relocation capabilities.