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Clean Assembly Hall H9/H10 – Advanced Testing of Offshore Cranes

The newly built Clean Assembly Hall (H9/H10) is a strategic investment that significantly expands Expom’s capabilities in the assembly, outfitting and testing of advanced crane structures.

The facility was designed for demanding projects, including special-purpose cranes intended for operation on vessel decks, offshore platforms and other harsh operating environments.

One of the first projects carried out in the hall involved the complete testing of two modern cranes manufactured for a Norwegian customer and designed for servicing drilling platforms.

The cranes feature a unique design. They are equipped with a travelling trolley running on steel wheels, allowing the units to move directly along the ship’s side. A hydraulic drive provides smooth movement and high reliability in demanding marine conditions.

The cranes have two independent working arms, which significantly increases their functionality.

One arm is equipped with an advanced gripping system for ropes and chains. It is used for precise installation operations, such as the installation of buoys and anchors.

The second arm is designed for lifting loads. It has a working radius of up to 15 metres and a lifting capacity of up to 3 tonnes at maximum outreach.

The entire system is remotely controlled. This improves operator safety and working comfort.

One of the key design features of the H9 hall is the retractable roof with a 9 × 24 metre opening. This solution significantly expands the possibilities for assembling and testing advanced crane systems.

Thanks to the retractable roof, cranes exceeding the standard height of the hall can be assembled and tested without moving them outside.

In practice, this means that equipment with an outreach of more than 18 metres can be fully assembled, equipped and tested inside the hall, regardless of the season or weather conditions.

Moving the testing process from a traditional outdoor test area into the hall provides several important operational benefits:

  • Independence from weather conditions – rain, wind, frost and high temperatures do not affect the work schedule.
  • Controlled assembly environment – stable temperature and no exposure to dust, mud or moisture.
  • Higher precision during assembly and testing – hydraulic, pneumatic, electrical and electronic systems can be installed under stable conditions.
  • Shorter project lead time – delays caused by weather conditions are eliminated.
  • Improved work safety – assembly and testing are carried out indoors, without exposure to rain, snow or strong wind.

The H9 hall is equipped with three independent test stations, providing another major operational advantage.

Main test station

The main station is designed for testing the largest and heaviest cranes. It allows static tests with loads of up to 1,600 tonne-metres.

The station is equipped with a dedicated test rail and advanced load application and support systems. These systems allow operating conditions close to real service conditions to be reproduced.

Two additional test stations

Each additional station allows testing of crane units with loads of up to 480 tonne-metres.

They can operate simultaneously with the main station. This makes it possible to test several projects at the same time.

This configuration allows up to three different units to be tested simultaneously. It significantly increases the production throughput of the facility and provides greater flexibility in project scheduling.

All test stations are located indoors. This means that even advanced tests involving complete operating cycles, dynamic loads, hydraulic power systems, electrical systems and electronic controls can be carried out throughout the year.

The testing process is not interrupted by adverse weather conditions.

The hall is equipped with a range of specialist systems supporting the testing of complex crane systems:

  • Test rail – allows mobile cranes to be tested under conditions close to actual operation, for example by simulating operation on a vessel deck.
  • Utility supply systems – hydraulic, pneumatic and electrical connections, as well as power supply for electronic systems and automation.
  • Control and monitoring system – enables real-time recording of operating parameters. This functionality will be available soon.
  • Clean assembly environment – a controlled area with reduced dust and contamination. This is important when installing precision systems, advanced sensors and electronic components.

The tests carried out on the two cranes for the Norwegian customer covered a comprehensive range of checks, including:

  • Static tests – verification of structural strength under maximum load and overload conditions.
  • Dynamic tests – operation of the arms through their full range of movement, lifting and lowering of loads, and testing of the hydraulic system.
  • Control system tests.
  • Drive system functional tests.
  • Advanced gripper system tests.
  • Remote control system tests.

The results confirmed the high manufacturing quality of the cranes and their full readiness for operation in demanding offshore environments.

The retractable roof also made it possible to perform full load lifting tests at maximum height. There was no need to move the crane outside and then reinstall it inside the hall.

This significantly reduced the project lead time and improved working conditions for the assembly and testing teams.

The commissioning of the Clean Assembly Hall is an important step in the development of Expom’s production and testing capabilities.

The facility not only increases production throughput. More importantly, it allows Expom to execute highly demanding projects for customers around the world, particularly in the offshore, marine and heavy industry sectors.

Thanks to:

  • the retractable roof,
  • three independent test stations,
  • a controlled assembly environment,
  • advanced technical infrastructure,

Expom has expanded its range of integrated manufacturing services.

These services cover the complete production process – from welding and painting, through mechanical equipment assembly and installation of hydraulic, pneumatic, electrical and electronic systems, to complete final testing.

The testing of the cranes for our Norwegian customer is a good example of how modern production and testing infrastructure supports innovative solutions in the marine and offshore industries.

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Steel, Precision and Scale – The Foundation for a 150-tonne Crane

We have completed a King-type steel structure designed to support a 150-tonne crane equipped with two winches. This project clearly demonstrates our capabilities in manufacturing heavy steel structures for demanding industrial and offshore applications.

Key structure parameters:

  • Self-weight: over 22 tonnes
  • Height: nearly 5.5 metres
  • Slewing bearing ring diameter: almost 4 metres

Structures of this size and load level require not only advanced production facilities, but above all experience in working with tight dimensional tolerances, critical welds and components designed to withstand high dynamic loads.

The King-type structure is the main load-bearing component of the entire crane system. The slewing bearing is mounted directly on this structure and allows the crane to rotate through a full 360°.

This means that the structure must withstand not only its own static loads, but also dynamic forces caused by boom movement, load lifting and changing operating conditions. These conditions can be particularly demanding in marine and offshore environments.

The entire project was completed at our facility – from receiving the technical documentation, through production, to final preparation for shipment. The process included:

  • Preparation and machining of steel components – cutting heavy-gauge plates, precision drilling of mounting holes and bending components to the required angles.
  • Welding – execution of critical welds with full quality control and process documentation.
  • Assembly and dimensional inspection – verification of geometry, dimensions and perpendicularity of the mounting surfaces.
  • Complete painting process – surface preparation, application of corrosion protection systems and topcoats suitable for demanding operating conditions.

Each stage was carried out with a focus on durability, precision and reliability. The structure is a critical part of the complete crane system.

Particular attention was paid to the slewing bearing mounting area. The contact surfaces, mounting holes and dimensional tolerances were manufactured with high precision. This ensures correct bearing installation and reliable operation of the complete system over many years.

This project demonstrates that we are ready to take on large-scale and highly complex projects where quality, process responsibility and a strong partnership with the customer are essential.

Structures of this type require more than production capacity. They also require complete infrastructure for machining, welding, painting and internal handling of large components.

Expom has all these capabilities in-house. This allows us to deliver complete projects – from raw material to finished product – without relying on subcontractors for critical production stages.

We are proud to have completed this demanding project and delivered a structure that meets the highest quality standards.

It is another example that steel, precision and scale are all within our capabilities – both technically and organisationally.

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Another Challenging Heavy Transport Operation Completed by Expom

During the night of 11–12 March 2026, Expom completed another specialist heavy transport operation. At 10:00 p.m., two transport units carrying trolleys designed for port cranes left our facility.

Transported element parameters:

  • Length: 11 metres
  • Width: 5.8 metres
  • Weight: just under 33 tonnes each

Loading such large and heavy components requires not only suitable equipment, but above all precise coordination and experience. Every stage of the operation – from preparing the structures, through loading and securing the cargo, to route planning – must be carried out with the highest level of care.

The Expom logistics and production teams made sure that the entire operation was carried out efficiently and safely. After careful preparation and securing of the cargo, the transport units set off, starting another stage of this demanding transport operation.

Projects like this show that Expom not only manufactures advanced steel structures, but also has the capability to professionally manage the entire logistics process – from assembly and loading to final delivery to the customer.

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From Simple Steel Structures to Marine Giants – Lifeboat Davits at Expom S.A.

Just a few years ago, few people could have predicted that Expom would manufacture more than one hundred specialized lifeboat davits – equipment that has now become one of the key projects delivered by our company for the marine industry.

A company once known mainly for manufacturing steel structures with basic paint systems has undergone an impressive technological and organizational transformation.

Today, Expom is a fully integrated production center for advanced lifting equipment. We manage the entire process in-house – from material procurement, fabrication and welding, precision machining, and high-performance coating systems, to final testing and commissioning.

The development of employee competencies, investments in machinery, and the construction of dedicated clean assembly halls have enabled us to master the complete production process of lifeboat davits in an end-to-end manufacturing model.

This means that every stage of production, regardless of complexity, is performed internally. As a result, we maintain full quality control while providing safe and efficient working conditions.

The lifeboat davit production process at Expom includes:

  • material cutting and preparation,
  • advanced fabrication and welding operations,
  • precision machining,
  • high-grade marine coating systems,
  • complete mechanical and hydraulic outfitting,
  • functional and load testing in the clean assembly hall.

Each davit leaves our facility as a fully completed product, ready for installation at the customer’s site.

Manufacturing cranes and davits designed for harsh marine environments requires not only experience and specialized expertise but also excellent organization.

Every operation is carefully analyzed and planned in advance. Production processes are implemented to meet strict quality and safety requirements.

Internal logistics, production planning, and quality control form the foundation of the entire project. Precise coordination between all departments ensures smooth execution even for the most complex projects while meeting the highest industry standards.

When we started our first lifeboat davit projects, many people wondered whether such large and technically demanding equipment could really be manufactured at Expom.

Today, after producing more than one hundred complete lifeboat davits, we can confidently say that the effort was worthwhile.

The experience gained, the development of employee skills, and new technological capabilities have opened the door to the next stage of our growth.

Lifeboat davit manufacturing has become one of our flagship activities and a clear example of how far a company can progress by investing in people, technology, and organization.

We continue to improve our processes, increase automation, and expand our portfolio to meet the growing demands of the marine industry.

Today, Expom is more than a steel structure manufacturer – it is a trusted supplier of advanced marine lifting equipment delivered with complete outfitting and full testing.

And more than one hundred lifeboat davits represent only the tip of the iceberg of Expom’s capabilities.

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29-Metre Steel Structure – Another Successfully Completed Project by the Expom Group

The KONTER team has just completed one of the most interesting projects of recent months – a 29-metre-long steel structure designed for oversized cargo transportation. The project was entrusted to us by a customer who expected the highest quality standards and full compliance with technical documentation. Today, we are proud to say that the project was delivered successfully thanks to the commitment and professionalism of the entire KONTER team.

When we received the technical documentation, we immediately recognized that this structure would require exceptional accuracy. Our team carefully reviewed all requirements and prepared a detailed execution plan, allowing production to start efficiently and without delays. Good organization and effective communication between departments ensured a smooth workflow throughout the project.

Although a length of 29 metres is impressive, the structure was manufactured without any difficulties thanks to thorough preparation and the experience of our employees.

Every stage of production – from material cutting and fabrication to welding and final assembly – required precision and commitment. In a project of this size, every millimetre matters. For this reason, all components were accurately fitted and all welds were completed in accordance with the highest quality standards.

Before delivery, the structure underwent comprehensive inspections to verify full compliance with the technical documentation and readiness for operation under demanding transport conditions.

Manufacturing a structure of this size always presents logistical and organizational challenges. Production space must be properly prepared, component handling carefully planned, and all activities coordinated to ensure uninterrupted workflow.

As always, we successfully met these challenges through excellent teamwork and effective project coordination.

Large structures require an even greater focus on safety. Therefore, all work was carried out in accordance with applicable health and safety regulations. The entire project was completed without any incidents, which reflects the professionalism of both our employees and the HSE department.

The successful completion of a structure of such impressive dimensions confirms our capability to execute large-scale and demanding projects. The customer received a product manufactured exactly according to the technical documentation, delivered on time and built to a high quality standard.

This is another project that strengthens our position in the market and demonstrates that we are a reliable partner for challenging industrial projects.

The completion of this 29-metre steel structure was the result of the hard work of many specialists: engineers, fitters, welders, logistics personnel and quality inspectors.

We would like to thank every member of the team for their commitment, professionalism and attention to detail. Through our combined efforts, we continue to deliver projects that make a lasting impression and of which we can all be proud.

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Installation team on standby!

EXPOM has been proving its leading position in the production and assembly of steel structures for years . Thanks to our experience and knowledge of the industry , we carry out projects from start to finish – from production, through to assembly and technical support.

Our projects in numbers

In 2023 , we created a lime kiln with an impressive height of more than 40 metres. The project included the production, assembly and preparation of the infrastructure. Thanks to this implementation , we increased the efficiency of our client’s technological process. In 2024 , we worked with the sugar industry, installing a 26-tonne lasering machine. The project required the adaptation of the building and the modernisation of technological systems, such as:

  • Lime feed system.
  • Lime milk collection and transport system .

Each stage of the work was coordinated with the utmost precision, allowing the installation to be fully functional.

Why EXPOM?

  1. Comprehensive service – from design, through production, to installation and commissioning.
  2. Experience – we carry out complex projects in industrial sectors such as the energy, lime and food industries.
  3. Individual approach – we adapt existing infrastructure to new technological requirements.
  4. Punctuality and precision – we meet deadlines, ensuring the highest quality workmanship.

Take a look behind the scenes

See how our projects are made! Watch a video of a lime kiln installation or photos of a cane installation. Meet our team in action.
movie

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Polish offshore industry on the offensive!

seminarium PI

Polish offshore industry on the offensive!

Yesterday we had the pleasure of attending the XII OFFSHORE Academy Seminar organised by the Polish Chamber of Offshore Wind Energy with the support of Orlen Neptun. The event focused on the future of offshore wind farms – from the permitting process, to the key role of third party inspectors, to the details of construction.

📌 The seminar was not only a space for knowledge exchange, but also an opportunity to look at the technical and regulatory challenges that are driving the dynamic development of the offshore industry in Poland.
💡 What did we take away from the event? Inspiration and new ideas to help us be an even better partner in building the offshore energy infrastructure.

⚓ Offshore is the future – let’s build it together!

Polish Offshore Wind Industry Chamber (PIMEW)

Offshore EnergyMaritime WiatrowaEnergy Expom TechnologicalDevelopment

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Modern, clean assembly hall at Expom – investing in the future

hala czystego montażu, clean assembly hall

Modern, clean assembly hall at Expom – investing in the future

At Expom, we are constantly taking steps to strengthen our position in the market and offer our customers even more advanced technological solutions. The construction of a new clean assembly hall is one of the most important projects in our history – an investment that sets new standards in the steel construction and technical equipment industry.

First phase completed – modernity in action

In the first phase of the project, we have completed half of the construction work and the 1,500 m² hall is now ready for use. It is a space that has been created with a comprehensive range of production, testing and assembly needs in mind. We are already carrying out advanced processes in it:

  • Mechanical, hydraulic, pneumatic, electrical and electronic assembly,

  • testing of equipment, including lifeboat cranes and offshore equipment.

The hall is equipped with cranes of impressive capacity:

  • 2 x 20T,

  • 2 x 32T,
    allowing us to handle even the most demanding projects.

Infrastructure for the future

Our hall is not only an impressive space, but also an innovative architectural and technological solution. Two bays, 16m and 18m high, have been designed to accommodate a wide range of projects, from small elements to large steel structures.

Thanks to the latest equipment and ergonomic layout, our employees can work in even more comfortable conditions. Roofed assembly and testing stations allow production processes to be carried out regardless of weather conditions, resulting in higher quality and work efficiency.

Thanks to this investment, we have gained even greater flexibility and the ability to carry out the most advanced projects. It is also an opportunity to win new customers and strengthen the collaboration with our current partners.

Values that define us

The investment in the clean assembly hall is not only a response to the growing needs of the market, but also a demonstration of our commitment to technological development and social responsibility. For years we have focused on

  • innovation,

  • continuous development of production potential

  • high quality of the services offered,

  • working in partnership with our customers.

We are a company that understands the importance of combining tradition with modernity. Our history goes back more than 72 years, but thanks to constant investment in new technologies, we remain a leader in the steel structures and technical equipment industry.

For whom are we building our future?

The new clean assembly hall opens up a wide range of opportunities for us to work with customers from a variety of industries. We are particularly interested in

  • Acquiring new business partners who are looking for reliable suppliers in the field of production and assembly of advanced structures,

  • to re-establish cooperation with companies that have already used our services.

The expansion of our infrastructure will enable us to carry out an even greater number of projects, tailored to the individual needs of our customers. Thanks to this, we are able to meet even the most demanding orders, offering comprehensive solutions from design to final testing.

What are the advantages of working with Expom?

Thanks to the new hall, we are able to offer:

  • Faster order execution,

  • The possibility of testing equipment in better conditions,

  • comprehensive technical support at every stage of cooperation.

For our customers, this means not only higher quality of services, but also the certainty that their projects are in the hands of experts with many years of experience.

We invite you to cooperate with us!

If you are looking for a partner who understands the needs of the modern market and can provide solutions at the highest level, Expom is the right choice. The completion of our new investment is another step towards innovation and technological advancement.

Contact us today to find out how we can work together on ambitious projects.

Why is it worth following our progress?

The construction of the new hall is just the beginning of our ambitious plans. Stay tuned to our website and social media profiles for regular updates on progress, interesting projects and new opportunities to work together.

Expom – building the future together!

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Leading steel and RES companies form Expom Group

Another member company, Werex, which specialises in the production of welded structures, has joined the Expom Group. The expansion of the group brings strong opportunities and synergies.

In 2019, on the initiative of Expom SA, the Expom Group will be created, consisting of Expom SA, Konter, Expom Eco-Energy. From December 2023, the Expom Group will be extended to include another company, Werex.

Expom SA, founded in 1952, is one of the leading manufacturers of steel structures. The company provides services to international clients and has an impressive track record of projects that have gained market recognition. Werex, specialises in the manufacture of welded structures in black and acid resistant steel. Konter, is an experienced steel fabrication and erection contractor. Expom Eco-Energy, brings expertise in green energy and green concepts to the group. As a supplier of various renewable energy solutions, the company is perfectly in line with modern trends in ecology and sustainability.

„We have decided to invite companies whose experience and skills complement each other. I am convinced that joining forces will have a positive impact on the quality and innovation of the solutions we offer. The Expom Group now has a solid basis for further development, increasing its market presence and ability to implement even the most complex projects“. – says Rafal Domzalski, President of Expom SA.

Thanks to this strategic partnership, Expom Group will gain new business areas and the ability to offer comprehensive solutions to its clients. The integrated portfolio of services now includes not only steel structures, but also modern renewable energy solutions.

It is worth noting that the companies that make up the Expom Group share a similar mission and values. Each of the companies is committed to working in accordance with international quality standards, providing the highest level of customer service, employee safety, development and innovation.

„The Expom Group companies employ highly qualified technical staff, engineers and specialists. One of the Group’s priorities is the practical vocational training of young people, who will make up its future workforce. We are proud that our Group is a leader in the field of youth education in the region,” says Rafal Domzalski, President of Expom SA.

Expom Group stands for quality, implementation of innovative design solutions and sustainable development in the industry.

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EXPOM S.A. at the forefront of innovators in anti-corrosion trends – Frosio 2023 Symposium

On 20-21.11.2023 EXPOM participated in the 6th Frosio Inspectors Training Symposium and our delegation honoured this prestigious event with its presence. We are proud that, as specialists in the steel construction industry, we were able to give a lecture together with our valued customer addressing the correlation of surface preparation with the quality of the resulting spray coatings.

Our presentation generated great interest among the audience, provoking fruitful discussions on the classification of anti-corrosion service providers. We also emphasised the importance of pre-qualification of the process and personnel prior to starting anti-corrosion work. This was not just a lecture – it was an initiative that resulted in our invitation to continue our research in this area.

We are delighted with the trust placed in us and the opportunity to continue our research collaboration. Our company is driven by the highest standards and attention to quality, which allows us to be a leader in the steel construction industry.

We would like to thank the Symposium participants and our partner for their support and commitment. Together we are creating new standards and inspiring innovation in the industry. Keep an eye on our website to stay up to date with our research, projects and innovations.

Together we are changing the face of the industry! 💪🌐

#Frosio #SteelConstructions #Innovation #ScientificResearch #EXPOM

Lecture at the Frosio 2023 training course