Moving large power transformers inside a manufacturing facility is one of the most demanding material handling challenges in the energy sector. The units are heavy, often weighing hundreds of tonnes, bulky, and sensitive to shock and vibration. The floor, the building structure, and the production flow all place constraints on how movement can be achieved.
Solving has supplied customized transformer handling equipment to manufacturers and facilities across the world for nearly 50 years. Our Air Film Movers, also known as Air Bearing Movers or Air Cushion transporters, are used to move complete transformers weighing 500 tonnes or more through production areas, test facilities, and into vacuum ovens, efficiently and safely.
Beyond complete transformers, transformer production facilities also require safe and efficient handling of steel coils, steel sheet stacks, transformer cores, windings, transformer bushings, and other heavy materials throughout the manufacturing process. For handling of these, Solving offers customized Automated Guided Vehicles (AGV) and Wheeled Movers in addition to Air Film Movers.
What equipment is used to move heavy transformers?
The right handling solution depends on transformer weight, travel distance, floor conditions, required precision, and how frequently moves are made. Below is an overview of the main equipment types used in transformer manufacturing and assembly.
Air Film Movers (Air Bearing Movers) Platforms that float the transformer on a thin film of compressed air, virtually eliminating friction. Offer omnidirectional movement with millimeter precision and very low floor loading. Well suited for production environments where flexibility and precise positioning are priorities. Solving Air Film Movers handle loads from a few tonnes up to 1,000+ tonnes.
Wheeled Movers Robust, remote-controlled platforms on wheels, suited to longer transport distances. Solving Wheeled Movers are also available in telescopic configurations, for example for handling transformer bushings.
Automated Guided Vehicles (AGVs) Battery-powered vehicles navigating predefined routes. Well suited for continuous, repetitive movement of materials such as steel coils, steel sheet stacks and components along a production line. Solving AGVs are used in transformer factories for automated supply of materials throughout the manufacturing process.
Rail-guided transfer cars Fixed-route vehicles running on embedded rails. High capacity and reliable for repetitive production flow between fixed stations. Require significant civil works and offer limited layout flexibility.
Overhead bridge cranes The traditional backbone of transformer assembly. Essential for vertical lifting (core stacking, coil insertion, tanking), but expensive at very high capacities, and create suspended-load hazards. Most transformer plants use cranes in combination with floor-based transport rather than as the sole handling method.
Self-propelled modular transporters (SPMTs) Multi-axle hydraulic platforms capable of very high capacities. Flexible routing without rails. Typically used for occasional large moves or where routing changes frequently.
How do Air Film Movers (Air Bearing Movers) work for transformer handling?
An Air Film Mover carries the transformer on a platform equipped with air bearings, also called air casters. Compressed air is supplied to each air bearing, forming a thin film of air between the air bearing and the floor. The transformer and platform float a fraction of a millimeter above the surface.
Because there is virtually no contact between the air bearing and the floor, friction is almost zero. This means a transformer weighing several hundred tonnes can be moved and steered with a small applied force, and positioned with millimeter accuracy. The Mover is typically operated by a single person using a remote control unit.
Solving Air Film Movers can be equipped with electric drives and integrated batteries. When unloaded, the Mover can operate independently of hoses and cables. Connection is only required when moving a loaded steel pallet.
The low profile of the air bearings and the compact design of the Air Film Mover means the total height of the handling equipment remains very low. For large transformers where height clearance in production areas, test bays, or vacuum ovens is critical, this is an important practical advantage.
Handling of steel coils
Steel coils are used as raw material in the production of transformer core laminations. AGVs are well suited for the automated, repetitive transport of coils along the production line, supplying material continuously to the core lamination process without manual forklift operations. Automating this stage of the process reduces handling risks and keeps production flow consistent.
Handling of steel sheet stacks
Steel sheet stacks are produced from the coils and used to build transformer cores. Like coils, sheet stacks are heavy and moved repeatedly as part of the core lamination production process. Solving Movers handle the automated supply of sheet stacks along the production line, ensuring a steady and reliable flow of material between workstations.
Handling of transformer cores
Transformer cores are large, heavy structures assembled from steel sheet laminations. Once assembled, the core must be transported carefully between production stations without shock or vibration. Solving Movers are used to move and position transformer cores smoothly and precisely.
Handling of transformer windings
Transformer windings and active parts require careful, controlled handling throughout the assembly process. Solving Air Film Movers and Wheeled Movers provide the precision and smooth movement needed to transport windings safely between production stages.
Handling of transformer bushings
Transformer bushings are tall, fragile components that require a stable and precisely controlled handling solution. Customized Solving Wheeled Movers are available in telescopic configurations specifically designed for bushing transport, providing the support and control needed to move bushings safely through the production area and position them accurately for installation.
Air Film Mover and Wheeled Movers versus overhead crane – when to use which
Overhead cranes and Air Film Movers or Wheeled Movers are complementary rather than competing solutions in most transformer facilities.
Cranes are essential for vertical operations: lifting cores, inserting coil assemblies into tanks, installing covers, and other tasks where the load must be raised. They are difficult and expensive to replace for these operations.
Air Film Movers and Wheeled Movers are better suited for horizontal transport: moving complete transformers between production stations, positioning units inside test bays, transferring heavy loads through production areas and into vacuum drying ovens. A single Air Film or Wheeled Mover operated by one person can move heavy transformers smoothly and precisely, without the overhead infrastructure cost of a crane rated to the same capacity.
Using floor-based transport for station-to-station movement also frees the crane for value-adding assembly work, reducing crane congestion and improving overall production flow. Many transformer manufacturers find this hybrid approach delivers significant throughput and safety benefits compared to relying on cranes for all movement.
Transformer handling applications
Solving AGVs, Air Film Movers and Wheeled Movers are used at multiple stages in transformer manufacturing and in repair and maintenance facilities:
- Handling steel coils and steel sheet stacks for core lamination production
- Automated supply of raw materials and components along the production line (AGVs)
- Transporting transformer cores, windings, and active parts
- Moving and positioning transformer bushings, including telescopic handling configurations
- Moving active parts in and out of vacuum drying ovens
- Positioning units inside test facilities and test bays
- Moving complete transformers through production areas and between assembly stations
- Handling in transformer repair workshops
- Facilities where crane access is limited or the load exceeds practical crane capacity
The transport route can be changed at any time without modifications to the building. No fixed floor installations, such as rails, are required.
Discuss your transformer handling requirements with Solving
Solving has nearly 50 years of experience supplying customized handling equipment to transformer manufacturers worldwide. Customers include ABB, Siemens, and Wilson.
If you are planning a new facility, upgrading an existing production line, or looking for a more efficient way to move transformers, we are happy to discuss your specific requirements. Book a free consultation!
Transformer handling in practice: Customer cases
See how transformer manufacturers have solved their handling challenges with Solving equipment:
- How Tamini Trasformatori moves 250–500-tonne transformers with Air Film Movers
- Wilson Transformer invested in a third Air Film Mover
- A customized Mover handles transformer bushings in a narrow layout
Frequently asked questions about moving transformers (FAQ)
- What is the safest way to move a large power transformer inside a manufacturing facility?
For most production environments, an Air Film Mover (Air Bearing Mover) provides a safe, controlled, and floor-friendly solution. The load floats on air, eliminating friction and floor wear. Movement is slow, smooth, and precisely controlled by one operator. The transformer’s weight is distributed over a large surface area, resulting in very low point loads on the floor. For vertical operations such as lifting and assembly, overhead cranes remain necessary. - What equipment options exist for moving transformers weighing 100–500 tonnes?
The main options are Air Film Movers, Wheeled Movers, rail-guided transfer cars, SPMTs, and overhead cranes, often used in combination. Air Film Movers are particularly well suited for flexible indoor movement where precision matters. Solving Air Film Movers are a cost-effective solution for loads of 1,000 tonnes or more when compared to cranes. - How do Air Film Movers work for transformer handling?
The transformer is placed on a platform equipped with air bearings. Compressed air forms a thin film of air between each air bearing and the floor. The load floats with virtually no friction, allowing heavy transformers to be moved and steered with minimal force and positioned with millimeter precision. - What floor conditions do air bearings require?
The floor must be flat, non-porous, free of significant steps and cracks, and have a smooth finish. Ideally a power-trowelled concrete surface. For occasional moves on a substandard floor, steel or PVC sheet can be used as a travel surface. - We are planning a new transformer production facility. What material handling should we consider?
Most modern transformer facilities combine high-capacity overhead cranes for assembly operations with floor-based transport (Air Film Movers, Wheeled Movers, or AGVs) for station-to-station movement. The right combination depends on transformer size, production volume, and layout. Solving offers a free consultation to help identify the most suitable handling system for your requirements. - Our factory currently uses overhead cranes for all transformer movement. What are the alternatives?
Air Film Movers and Wheeled Movers are the most common floor-based alternatives for horizontal transport in transformer facilities. Moving units between stations on the floor, rather than under crane, reduces crane congestion, lowers the risk of suspended-load incidents, and can improve overall production flow. Most transformer plants adopt a hybrid model, retaining cranes for assembly lifts while using floor-based transport for movement between stations. - What is the maximum weight a Solving Air Film Mover can handle?
Solving Air Film Movers are a flexible solution for handling loads of 1,000 tonnes or more. Complete transformers weighing 500 tonnes or more are regularly handled by one or two Movers that are interconnected. Each system is customized to the specific load and facility requirements.