Relocating big kit is never “just a lift”; it’s a construction project with safety, uptime and budget on the line. The short version: plan under CDM, survey access and ground conditions, choose the right lifting method, protect power/air/controls on the critical path, and commission like you mean it. Avoid the traps below and your move will be safer, faster and cheaper.
1) Treating it like a simple transport job
Heavy moves involve construction-like risks, so govern them properly. Appoint CDM duty holders, write RAMS, and coordinate permits, isolations and temporary works. Skipping this often leads to late stops, rework and cost overruns.
Authoritative resource (non-competitive): HSE guidance on LOLER (Lifting Operations and Lifting Equipment Regulations): https://www.hse.gov.uk/work-equipment-machinery/loler.htm
2) Poor surveys: access, floor loading and ground bearing pressure
Common misses include door widths, corridor turns, low services, slab capacity and external ground bearing for crane outriggers. Get structural checks and ground bearing calculations done early—or risk mid-lift stand-downs and emergency matting hires.
3) Using the wrong lifting method
Toe jacks and skates, Versa-lifts/hydraulic gantries and mobile cranes each have a sweet spot. Mismatch the method and you’ll burn time and budget, or worse, damage assets. Build a lift plan that reflects mass, centre of gravity (CoG), height, footprint and route.
4) Forgetting centre of gravity and stability
Guessing CoG is a classic error. Weigh and mark it, use the right spreader beams/sling lengths, and allow for fluids or tooling still on board. Always run a test lift and verify clearances before committing.
5) Weak decommissioning and labelling
Unclear isolation points, missing lock-off, and unlabeled cables/pneumatics slow recommissioning and invite faults. Photograph, tag and colour-code everything; bag fixings; create simple re-fit maps for each machine.
6) No backups of control systems
Moving day is the worst time to discover a corrupted PLC or HMI. Back up programs, recipes, parameters and network settings. Keep versions and passwords with the move pack—and test restores before you roll.
7) Under-protecting the asset
Insufficient bracing, poor wrapping, no desiccants, and unprotected sensors/HMIs cause hidden damage. Use shrink-wrap, transit braces, caps, transit locks and shock/tilt indicators; remove fragile appendages where practical.
8) Skimping on spares and temporary services
A £10 sensor can idle a £1m line. Carry a spares kit (belts, seals, sensors, fuses, safety relays) and plan temporary power, air and lighting so commissioning doesn’t stall.
9) Underestimating transport complexity
No route survey, wrong permits, or ignoring bridge heights and timed access can unravel a good plan. Confirm insurance levels, responsibilities and condition reports pre- and post-move, with photos.
10) Rushing commissioning and compliance
Powering up isn’t the finish line. Level and align, run dry-to-product trials, and complete PUWER checks, interlocks and E-stops before first saleable product. Document SAT results against acceptance criteria.
How FESS Group helps
FESS Group’s heavy equipment moving specialists handle surveys, lift plans, decommissioning, lift-and-shift, transport, re-installation, alignment and recommissioning—plus mechanical, electrical and controls integration. We phase works around your production windows to cut downtime and risk.
Quick checklist to avoid costly mistakes
- CDM duty holders appointed; RAMS and permits agreed
- Access, slab loading and ground bearing verified; lift plan approved
- Correct lifting method, gear, mats and exclusions booked
- CoG confirmed and marked; test lift planned
- Full decommissioning, labelling and photo records completed
- PLC/HMI backups taken and tested; passwords secured
- Protection fitted: bracing, wrap, desiccants, shock/tilt indicators
- Spares and temporary services arranged
- Route survey, permits, insurance and condition reports in place
- SAT, PUWER and run-rate acceptance criteria defined
FAQs
1) What’s the biggest cause of damage during a move?
Uncontrolled loads from poor CoG management or the wrong lifting gear, followed by inadequate protection of sensors, HMIs and product-contact parts.
2) Do we always need a crane?
No. Internal moves often favour skates and toe jacks; tall/heavy assets may suit hydraulic gantries or Versa-lifts. Choose the method that fits mass, height and access.
3) How do we keep downtime low?
Pre-assemble off-line (skids, panels), back up controls, label everything and plan temporary services. Phase by line/cell and commission with clear go/no-go criteria.
4) Are PUWER and LOLER required for machinery moves?
Yes—LOLER governs the lifting operation and gear; PUWER applies before the machine is used post-move. Log inspections and keep records with the asset file.
5) What insurance cover should we check?
Confirm goods in transit, public/employers’ liability, and whether cover is on full replacement value. Agree photographic condition reports and sign-off on both ends.
Ready to move heavy machinery with less risk, cost and downtime? Book a consultation or request a site assessment today: https://fessgroup.co.uk/services/heavy-equipment-moving-companies/
