In the context of heavy industry and large-scale industrial plants, large-scale mechanical machining is a strategic activity to ensure operational continuity, efficiency, and safety of production assets. Working on components of significant mass and complexity requires advanced technical expertise, dedicated equipment, and a deep understanding of issues related to large-scale mechanical maintenance.
This article explores the main types of large-scale machining operations, the services offered by Nuova Simat, and the state-of-the-art portable machines used to operate directly in the field, even in critical situations and challenging environments.
What Large-Scale Mechanical Machining Is
When It Is Required and in Which Industrial Sectors
Large-scale mechanical machining includes a series of material removal, geometric restoration, or structural modification operations on mechanical components with large volumes or significant weights. These operations go well beyond the limits of traditional workshops, involving portable machine tools, automated systems, and custom technologies designed to adapt to the workpiece, often installed directly on the plant.
These activities are essential in high-value strategic sectors, including:
- Wind energy (e.g., turbines and supports),
- Oil & Gas (e.g., valves, flanges, heat exchangers),
- Shipbuilding industry,
- Steel and metallurgy industry,
- Power generation plants.
Definition and Application Areas
Large-scale mechanical machining becomes indispensable in cases of:
- Failures of critical non-transportable components,
- Mechanical wear on components in operation,
- Structural deformations caused by thermal stress or vibration,
- Plant modification or upgrade works.
Thanks to mobile technologies and specialized personnel, on-site machining can be performed without disassembly, reducing downtime and logistics costs. This approach is particularly advantageous for industrial operations running 24/7 that cannot afford prolonged production stoppages.
Nuova Simat: Industrial Machining Services
On-Site Machining Operations
On-site machining represents one of the main strengths of Nuova Simat. Thanks to mobile technologies and high-precision positioning systems, the company can perform milling, turning, boring, and reaming operations directly on site, without the need to disassemble or transport components to a workshop.
This approach allows a significant reduction in plant downtime, a decrease in logistics costs, and an increase in maintenance efficiency, making it ideal for power plants, refineries, steel mills, cement plants, and medium to large industrial machinery.
Special Machining on Request
Nuova Simat offers custom mechanical machining services based on client specifications, even for non-standard geometries or high-complexity materials. These operations, which can also be performed by our specialized operators, often involve the design and fabrication of custom solutions and equipment to ensure perfect adaptation to real operating conditions.
The most requested operations include:
- Reprofiling of mating surfaces,
- Reconstruction of damaged mechanical seats,
- In-situ geometric corrections,
- Mechanical alignments and precision re-couplings.
Industrial Plant Maintenance and Restoration
In addition to extraordinary interventions, the company also provides scheduled mechanical maintenance aimed at restoring the efficiency of worn or out-of-tolerance components. Technicians work in close cooperation with the client’s engineering and maintenance departments, providing customized solutions that take into account the actual operating conditions.
The service includes:
- Technical diagnostics and dimensional surveys,
- Corrective interventions on installed components,
- Support for revamping and plant upgrades.
Technologies and Machinery for Large-Scale Machining
To meet the demands of precision, speed, and reliability in large-scale mechanical machining, Nuova Simat employs a selection of advanced portable machines designed to operate directly on-site. Below are some of the main systems used in our operations, chosen for their performance, versatility, and ease of transport to work sites.
Modular Linear Milling Machine MM-6000
The MM-6000 is a portable modular linear milling machine that enables the milling of large flat surfaces directly on-site.
Designed for high-precision work, it is ideal for:
- Machining flat mounting bases,
- Milling frames, supports, and industrial structures,
- Restoring damaged or out-of-tolerance surfaces.
Portable Electro-Erosion System ARES 500
The ARES 500 is a portable electrical discharge machining (EDM) system, designed to remove studs, broken bolts, pins, or seized metal components inside threaded holes without damaging the original seat.
Main advantages of the EDM system:
- High precision and process control,
- No mechanical stress on the component,
- High operational flexibility.
Boring Machine for Power Joints BS-060
The BS-060 is a compact portable boring machine for machining power joints, pin housings, cylindrical seats, and concentric holes. Its design makes it ideal for use in confined spaces or on components still installed.
- Fast and accurate centering system,
- High rigidity and machining stability,
- Capability for medium and large diameter machining.
Induction Heating System Helios 35+
The Helios 35+ is a portable magnetic induction heating system designed for controlled heating of metal components before mechanical operations (e.g., disassembly, expansion, or interference fits).
Main advantages:
- Rapid, targeted heating,
- No open flame for greater safety,
- Extreme portability for all types of sites.
Comparative Table of On-Site Machining Equipment
| Machine | Operation Type | Main Applications | Strengths |
|---|---|---|---|
| MM-6000 | Linear milling | Flat bases, supports, frames | Modularity, high precision, portability |
| ARES 500 | Portable EDM | Removal of studs and bolts | No deformation, high precision |
| BS-060 | Boring | Power joints, cylindrical seats | Compactness, rapid centering, stability |
| Helios 35+ | Induction heating | Bolting, interference assemblies | Safety, flame-free, speed |
Advantages of On-Site Mechanical Machining
Reduction of Plant Downtime
On-site operations avoid disassembly and transport of components, drastically reducing downtime and accelerating the return to full production.
Higher Precision and Rapid Response
With high-precision machines and qualified technicians, machining is fast, accurate, and with minimal error margins, even in complex environments.
Reduced Need for Disassembly and Transport
Being able to work directly on-site eliminates handling costs and minimizes risks associated with logistics for large components.
Why Choose Nuova Simat for Large-Scale Machining
A Technical Partner with Proven Field Experience
Nuova Simat has been a benchmark in the field of industrial mechanical machining for over 30 years, with consolidated leadership in bolting and portable machine technologies. The company’s direct field experience allows it to provide practical, proven solutions, backed by unique operational expertise.
The portable machine tools used in on-site services are the same units available for rental or sale, tested and operated by our technicians in numerous service operations. This guarantees not only technical reliability but also a perfect match between theory and practice in equipment use.
Extensive Machinery Fleet and Customized Solutions
At our recently renovated headquarters, we have:
- A permanent showroom with machines in operational setup where live demonstrations can be requested,
- An internal workshop equipped for maintenance, preparation, and testing of machines,
- A fully stocked spare parts warehouse,
- Immediate availability of replacement machines to ensure operational continuity.
Our well-equipped workshop allows us to quickly make available for rental a wide range of machines, including:
- Pipe cutters and beveling machines,
- Boring and linear milling machines,
- Portable lathes,
- Drills, tapping units, grinders,
- Flange facing systems,
- Equipment for hydraulic and induction bolting,
- Tools for grinding and lapping,
- Custom solutions designed according to client specifications.
Integrated Services, Training and Technical Support
Our technical office is always available to support the client in choosing the most suitable solution, providing:
- Tailored engineering consultancy,
- Technical analysis of machining issues,
- Operational support during all project phases.
In addition, we offer:
- Direct sale of equipment,
- Operational rental with or without operator,
- Fast repairs and temporary replacements,
- Professional training courses on equipment use,
- Technical case histories for evaluating similar interventions.
Customer Focus and Certified Quality
We stand out for our ability to provide quick, effective responses to operational needs while maintaining a high-quality standard. Field experience has enabled us to select only top-level, reliable and high-performing equipment.
We believe in proactive, timely customer care, focused on achieving complete client satisfaction. We are present, available, and responsive throughout every stage of the process—from initial analysis to on-site intervention to post-service support.
For Nuova Simat, customer satisfaction is the most important result.
Request a Personalised Consultation
Large-scale mechanical machining requires experience, the right tools, and customized solutions. Nuova Simat is a reliable partner for fast, precise, and certified technical interventions directly in the field.
Contact the technical team of Nuova Simat for a tailor-made quotation or an on-site technical visit.
FAQ: Frequently Asked Questions About Large-Scale Mechanical Machining
Is it possible to request an urgent machining operation with short response times?
Yes. Nuova Simat is structured to handle urgent interventions thanks to a lean internal organization, a fully equipped workshop for immediate machine preparation, and operational technicians available 24/7 for field services. Depending on the complexity of the task, an operation can be planned within just a few hours.
Can the equipment be rented without an operator?
Yes, all portable machines can be provided either in simple rental or as part of a full service (rental + specialized operator). Nuova Simat also offers personalized technical training for client personnel wishing to operate independently.
What are the main advantages of on-site machining compared to workshop machining?
On-site operations eliminate the need for disassembly, reducing both time and costs while improving safety and precision.
Are on-site mechanical machining operations certified?
Yes. All operations follow documented technical protocols, with certification of final measurements.
