5 Ways Equipment Damage Happens During a Move — And How to Prevent It
When relocating industrial equipment, damage isn’t always dramatic. It can be subtle, costly, and easy to miss until it’s too late.
Whether it’s a bent shaft, a crushed conduit, or a misaligned baseplate, damage leads to unplanned downtime, expensive repairs, and even safety hazards.
Here are the 5 most common causes of damage during a plant or equipment relocation, and how to prevent them with the right planning and execution:
1. Improper Rigging Techniques
The risk: Forklift forks puncturing housings. Straps stressing mounts. Uneven lifting causing internal misalignment.
Why it happens: Not all riggers are trained for specialized machinery. Quick lifts can overlook center of gravity, attachment points, or load balance.
How to prevent it:
Use engineered lift plans for heavy or delicate equipment
Require OSHA/ASME-trained rigging crews
Document rigging points and lifting clearances ahead of move day
2. Inadequate Protection During Transit
The risk: Vibration damage, unsecured internal components, weather exposure, or impact inside the trailer.
Why it happens: “Just strap it and go” doesn’t cut it for sensitive equipment.
How to prevent it:
Crate or cover high-precision or moisture-sensitive equipment
Use air-ride trailers when needed
Secure internals (e.g., spindles, tool changers, gauges)
3. Missed Disconnection Steps
The risk: Cut wires instead of tagged disconnects. Pressurized lines left open. Control panels not safely isolated.
Why it happens: Rushed prep or unclear accountability.
How to prevent it:
Assign a disconnect specialist
Follow an MOP (Method of Procedure) with photos and tags
Create reinstallation binders with clear labeling
4. Inadequate Floor Planning at the New Site
The risk: Equipment gets wedged, dropped, or damaged during last-minute layout changes.
Why it happens: Final layout doesn’t match reality. No space to maneuver.
How to prevent it:
Conduct pre-move walkthroughs at the destination
Model lift and placement paths in CAD
Stage equipment in sequence
5. Relying on Movers Who Don’t Specialize in Industrial Equipment
The risk: Low liability coverage. No experience with high-value assets. Lack of coordination with trades.
Why it happens: Choosing a general contractor or mover based on cost instead of capability.
How to prevent it:
Ask about liability limits and past experience
Require documented risk plans
Partner with a team that’s moved facilities like yours
Bottom Line: Damage Doesn’t Just “Happen.” It’s Preventable.
At Henke, we’ve moved everything from presses weighing tens of thousand of pounds, to live cleanroom equipment, with zero damage.
That’s not luck, it’s process, planning, and a culture of safety.