Projects Flagship Case Study

Concrete Batching Plant Relocation & Re-Engineering

A fast-track relocation project in Saudi Arabia that preserved capital assets, reduced downtime, and restored full production capacity at a new site.

Location: KSA Scope: Turnkey Relocation Goal: Production Continuity

The Challenge

The client owned an operational concrete batching plant that had to be relocated to a new site due to project logistics and land-use constraints. The priority was not just moving equipment — it was returning to production quickly and reliably.

  • Strict timeline to resume concrete supply.
  • Critical need to reuse existing equipment to control CAPEX.
  • New site presented different layout, foundations, and access requirements.
  • Requirement to restore production accuracy and reliability post-relocation.
"Simply moving the steel wasn't enough. The plant had to be re-engineered for the new site and calibrated for precision."

Project Objectives

To execute a safe dismantling and efficient re-installation while optimizing the plant for its new environment.

Safe Relocation

Dismantle and transport without damage to aging components.

Site Re-Engineering

Adapt layout to fit new site conditions and foundations.

Minimize Downtime

Parallel execution of civil works and equipment preparation.

Restore Accuracy

Full recalibration of weighing and dosing systems.

Single-Point Responsibility

Scope & Execution

Assessment & Planning

Feasibility and condition check.

  • Asset condition audit
  • Sequencing plan
  • Downtime strategy

Dismantling & Preserv.

Controlled removal and packing.

  • Electrical tagging
  • Component labeling
  • Transport packing

Logistics

Heavy equipment transport.

  • Route planning
  • Crane coordination
  • Handling supervision

New Site Engineering

Adapting to new ground.

  • Layout optimization
  • Civil foundations
  • Material flow design

Re-Installation

Mechanical erection & alignment.

  • Structural erection
  • Mechanical alignment
  • Electrical reconnection

Commissioning

Verification and restart.

  • System integration
  • Weighing calibration
  • Trial batching

Engineering Challenges Solved

Challenge 1

Layout Mismatch

Existing equipment was designed for a different geometry than the new site offered.

Our Solution:

We re-engineered the plant layout, optimizing material flow and access routes while reusing core equipment, avoiding the need for new purchases.

Challenge 2

Downtime Pressure

Concrete supply interruption had severe commercial impact on the client's projects.

Our Solution:

We implemented parallel execution of civil works at the new site while dismantling at the old site, enabling rapid reinstallation and minimizing the idle window.

Challenge 3

Restoring Accuracy

Relocated batching plants often suffer from calibration drift and mechanical misalignment.

Our Solution:

All weighing systems were fully recalibrated and load-tested. Mechanical alignment was verified with laser tools to ensure batching consistency.

Relocation & Commissioning Flow

1

Assessment

Status Check

2

Dismantling

Controlled Removal

3

Transport

Logistics

4

New Site Eng.

Foundations

5

Re-Install

Erection & Power

6

Restart

Commissioning

Engineered relocation with a focus on production continuity.

Project Outcomes

Operational

  • Full operation restored
  • Stable concrete production
  • Accurate batching verified

Commercial

  • Significant CAPEX saved
  • Minimal downtime achieved
  • Fast revenue return

Strategic

  • Plant remains relocatable
  • Improved maintainability
  • Safety upgrades included

Why This Is A Flagship Project

This project demonstrates our ability to relocate heavy industrial plants under time pressure. It highlights our expertise in preserving and reusing capital assets intelligently, re-engineering layouts for new site conditions, and executing safely in Saudi Arabia to restore production with confidence.

Relocate With Confidence

Need to relocate or reconfigure a concrete batching plant without compromising production or schedule? This project shows how engineering-led relocation delivers results.

Plan Your Plant Relocation

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