Modular Process Skid Fabrication
BSG fabricates skid frames and shop-welded skid piping for plant construction, process equipment builders and system integrators. We deliver the mechanical envelope, frame and piping, tested, coated and fully documented, so your team can mount equipment and commission on schedule.
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Process Skids We Fabricate
From compact dosing frames to full pipe rack modules, BSG builds the structural and piping scope of your process package across a certified network of Balkan fabricators.
Pump & Pressure Boosting Skids
Rigid base frames with machined and drilled mounting interfaces for pump sets, plus suction and discharge spools welded and pressure tested in the shop.
Dosing & Metering Skid Frames
Compact stainless or coated carbon steel frames for chemical dosing units, with containment trays, small-bore piping and tight-tolerance equipment interfaces.
CIP & Hygienic Process Skids
304L and 316L skid frames with orbital-welded sanitary piping, pickled and passivated, built to support CIP/SIP cleaning cycles in food, beverage and pharma plants.
Heat Exchanger & Thermal Modules
Heavy-duty frames sized for exchanger, vessel and buffer tank loads, with piping runs designed for thermal expansion, drainability and service access.
Filtration & Separation Skids
Frames and manifold piping for filtration, separation and water treatment packages, with valve manifold supports and full material traceability.
Pipe Racks & Custom Process Modules
Shop-fabricated pipe racks, module frames and structural sub-assemblies engineered from your 3D model, split into transportable sections where required.
Two Levels of Skid Supply
Start with a bare frame or take the complete mechanical envelope. Both levels are quoted, fabricated and documented as a single contract.
| Feature | Level 1 — Skid Frame | Level 2 — Frame + Piping |
|---|---|---|
| Structural skid base frame | ||
| EN 1090 EXC2 / EXC3 fabrication | ||
| Lifting lugs & transport securing points | ||
| Machined & drilled equipment mounting interfaces | ||
| Surface preparation & coating system | ||
| Drip tray / containment pan | On request | On request |
| Shop-welded process piping & spools | ||
| Pipe supports, brackets & guides | ||
| Hydrostatic or pneumatic pressure test | ||
| NDT (PT / RT / UT) per specification | ||
| Pickling & passivation (stainless) | ||
| Pumps, valves & instruments supplied and mounted | ||
| Electrical, control panel & wiring | ||
| Factory Acceptance Test (FAT) & commissioning |
Where our scope ends
BSG does not supply or mount rotating equipment, valves and instrumentation, and does not carry out electrical work, control panel integration or Factory Acceptance Testing. Those stay with you or your equipment vendors. We deliver the frame and piping prepared for them, with mounting interfaces machined to your drawing and dimensions verified before dispatch, so your assembly team starts without rework.
Transport Envelope & Fabrication Limits
Skid dimensions are driven by what can legally and economically reach your site. These are the limits we design and quote against for standard European road transport.
| Parameter | Specification |
|---|---|
| Max Skid Length | 13,600 mm (standard road trailer) |
| Max Skid Width | 2,550 mm standard / up to 3,000 mm with permit |
| Max Build Height | ≈ 3,000 mm on a standard trailer bed |
| Max Unit Weight | 24,000 kg per transport unit |
| Oversized Modules | Split into bolted or field-weld sections |
| Frame Profiles | UPN, IPE, HEA/HEB, RHS/SHS, plate girders |
| Piping Range | DN 15 – DN 600 (larger on request) |
| Frame Flatness | Levelled and shimmed to equipment tolerance |
| Coating Standard | ISO 12944, Sa 2.5 blast, 2–3 coat systems |
| Weld Quality Class | ISO 5817 level B or C per specification |
Skid Materials
Frame profiles, pipe and fittings sourced with full mill certification and traceability to the as-built drawing.
Structural Steel
- S355: default grade for skid base frames
- Excellent weldability across all grades
- Coated to ISO 12944 corrosivity category
- EN 10025 certified material supply
Stainless Steel
- 316L: standard for chemical and hygienic service
- Pickled and passivated after welding
- Ra < 0.8 µm internal finish available
- EN 10204 3.1 mill certificates
Duplex & Alloys
- High strength allows lighter wall thickness
- Chloride and pitting resistance for aggressive media
- Qualified procedures per EN ISO 15614-1
- Sourced with full traceability on request
From 3D Model to Delivered Skid
A streamlined process personally managed by BSG at every stage.
Submit Your Request
Send your 3D model, general arrangement drawing, P&ID and equipment data sheets. Our engineers confirm scope, transport split and code requirements within 24 hours.
We Match & Engineer
BSG selects a certified partner with the right frame and piping capability, and their engineers prepare shop drawings, qualified welding procedures and the inspection plan.
Production + Quality Control
We supervise frame fabrication, piping installation and coating, then manage pressure testing and the NDT scope agreed in your specification.
Delivered To You
One supplier, one invoice, one responsibility. Skids ship secured and ready for equipment mounting, with the complete documentation package.
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Design Guidelines for Process Skids
Decisions made early in skid design drive cost, transport feasibility and how easily the unit is maintained once it is in the plant.
Frame Design & Load Paths
- Equipment Load Points
- Mark on the GA drawing
- Frame Stiffness
- Limit deflection under load
- Levelling & Shimming
- Define flatness tolerance
Identify static and dynamic loads at each mounting point so the frame is sized for the real load path, not a uniform assumption.
Rotating equipment needs a stiff base; specify allowable deflection so pumps and motors stay aligned in service.
State the flatness required across mounting surfaces so the frame can be levelled and shimmed to the equipment supplier's limits.
Transport & Lifting
- Shipping Envelope
- 13.6 × 2.55 × 3.0 m
- Lifting Points
- Lugs or fork pockets
- Centre of Gravity
- Marked on the skid
Design within the standard EU road envelope; anything larger needs a permit, escort and a higher freight cost.
Specify lifting lugs, fork pockets or both, and confirm whether the skid is lifted loaded or empty.
We mark the calculated centre of gravity on the frame so site crews rig the unit safely on arrival.
Piping Layout & Drainability
- Slope & Drain Points
- Min. 1% fall to drains
- Dead Legs
- Avoid or keep < 2× DN
- Thermal Expansion
- Plan loops and guides
Slope process lines toward drain points so the skid empties fully, which is essential for hygienic and chemical service.
Dead legs trap product and cleaning fluid; keep branch stubs short or eliminate them at design stage.
Hot lines grow against a rigid frame; provide expansion loops, sliding supports or guides to avoid overstressing welds.
Maintenance Access
- Equipment Removal
- Clear extraction path
- Valve Operability
- Handwheel reach 500–1,700 mm
- Instrument Access
- Readable and reachable
Confirm that pumps, filter elements and exchanger bundles can be removed without cutting piping or dismantling the frame.
Position manual valves within comfortable operating height and leave clearance for the handwheel to turn freely.
Even when instruments are supplied by you, tapping points and gauge positions should be visible from the operating side.
Codes, Testing & Certification
- Frame Execution Class
- EN 1090 EXC2 / EXC3
- Piping Code
- EN 13480 or ASME B31.3
- Pressure Test
- Hydrostatic or pneumatic
State the execution class; EXC3 raises inspection and NDT requirements on the structural welds.
EN 13480 for EU installations, ASME B31.3 where the end client's specification calls for it.
Define the test medium, pressure and hold time in the specification so it is planned into the shop schedule.
Documentation Package
- Material Certificates
- EN 10204 3.1
- Welding Records
- WPS / WPQR + welder logs
- As-Built Dossier
- Drawings, NDT, test reports
Frame profiles, pipe and fittings supplied with 3.1 mill certificates traceable to the as-built drawing.
Qualified procedures per EN ISO 15614-1 and welder qualifications per EN ISO 9606-1, matched to each weld.
As-built GA and isometrics, NDT reports, pressure test protocol and coating report, issued as one dossier.
Frequently Asked Questions
Common questions about our process skid fabrication scope.
Why Companies Choose BSG
We combine Balkan production economics with European engineering standards and a single-contract model.
Confidence
You always know who manufactures your parts and how.
- Verified supplier network
- Full production transparency
- Direct factory communication
Control
BSG personally oversees the entire project from start to finish, working directly with engineers at our partner facilities.
- Dedicated point of contact
- Real-time progress updates
- On-demand inspections
Capacity
Access unused production capacity across a verified network of Balkan factories.
- 50+ manufacturing partners
- Scalable production volumes
- Multi-technology access
Cost Down
Lower European cost pressure without the logistical risks of moving production to Asia.
- 30-50% cost reduction
- 2-4 day EU delivery
- No ocean freight delays
Have a Skid Package to Outsource?
Send your 3D model and P&ID. BSG will confirm the transport split, select the right production partner and prepare a detailed quotation.