Pipe Racks

an advanced concept for industrial plant construction

Modular Design

Pipe Racks
Faster construction times, reduced costs and improved safety - pipe racks are becoming a key element of future-oriented industrial construction. The modular design enables precise planning, efficient prefabrication and flexible expandability — advantages that are critical to the success of complex projects.
Pipe racks are modular steel structures designed to carry piping systems and cable trays. Serving as the primary utility corridors, pipe racks function as distribution systems inside buildings and as pipe bridges outdoors. This concept is applied across multiple sectors, especially in the pharmaceutical industry and data centres. As a leading international engineering and construction contractor, ZAUNERGROUP provides fully integrated solutions. We approach every project holistically, managing the entire scope of work — from planning and prefabrication through to final assembly and commissioning.
Engineering
Our work starts with the basic design. At this early stage, we consider both the spatial and functional integration of the pipe racks within the overall plant layout. Addressing these aspects early minimises interface risks and improves the overall project schedule. Based on the initial specifications, ZAUNERGROUP develops the detailed engineering and refines it with practical, field-tested optimisations. The result is a concept precisely aligned with the plant’s technical requirements and a solid foundation for project success. We employ advanced digital tools throughout the process: Building Information Modelling (BIM) ensures seamless planning, our project management system ZGManage provides complete process transparency, and virtual-reality visualisations allow stakeholders to explore complex systems long before construction begins.
Prefabrication
Prefabrication takes place in our own production halls in Wallern (AT) and Satu Mare (RO), where optimal conditions ensure consistent quality. Modules of up to 24 metres in length and 22 tonnes in weight are produced here, precisely tailored to the specific requirements of each project. All components are designed in accordance with applicable standards, norms and legal regulations, and are executed with corrosion protection, hot-dip galvanisation, specialised coatings or entirely in stainless steel, depending on the project specifications. Through our just-in-time management, we minimise storage costs and ensure on-schedule delivery to site.
Assembly
The preassembled modules are transported directly to our construction sites across Europe, with special transports arranged when required by size or weight. ZAUNERGROUP handles the full coordination process, including permits and escort services. On site, our experienced teams assemble the individual racks into a fully functional unit. These heavy-lift operations are carried out with equal emphasis on efficiency and safety. Finishing works such as insulation, coating or heat tracing are also completed directly at the installation site.
Testing & Commissioning
Every component leaves our fabrication facilities only after thorough inspection and a successfully completed FAT. SAT procedures then verify full functionality under real operating conditions. This is accompanied by comprehensive documentation, ensuring maximum transparency throughout all project phases. Upon request, we also support flushing and cleaning of piping systems as well as the final commissioning process. By combining our own fabrication capabilities with innovative engineering tools and proven international installation expertise, we have become one of Europe’s leading partners for pipe rack solutions. Our expertise reflects technical excellence and maximum efficiency. We are shaping the future of industrial construction — with solutions that set new standards. Explore our case studies to see how we deliver complex plant solutions.
Our extensive large-scale project experience ensures technical precision and efficiency. Explore our cases to see how we realise complex plant solutions.