Challenges in moving large-format PVC sheets in production: Issues and effective solutions
23-9-2025
The production of large-format PVC sheets is a cornerstone of many modern structures — from biogas plants and stadium roofing to pneumatic halls, as well as flexible tanks for water and fertilizers. However, despite their immense potential, their size, weight, and physical properties make handling them during production a significant logistical, ergonomic, and technological challenge.
In this article, we will show you the key difficulties manufacturers face and the solutions — both technological and organizational — that can transform your production line.
Where Are Large-Format PVC Sheets Used?
PVC is a highly versatile material, applied wherever durability, flexibility, and resistance to weather conditions are required. The most common applications include:
- Biogas membrane production
Used to seal tanks and domes, often exceeding widths of 40 meters.
- Stadium roofing production
Modern membrane roofs for sports stadiums and event venues requiring large, durable, and flexible coverings (e.g., Olympiastadion Berlin, Stadion Śląska Wrocław).
- Air dome (pneumatic hall) production
Lightweight sports or industrial structures where PVC film acts as the primary cladding, often covering more than 1,800 m².
- Flexible tank production (e.g., for water or fertilizers)
Mobile storage tanks for water, slurry, or liquid fertilizers, requiring precise welding of large PVC sheets.
- Swimming pools and retention reservoirs
Lined with thick PVC foil to ensure tightness and durability.
Common Challenges in Handling Large PVC Sheets
- Weight and size
Large sheets can weigh several hundred kilograms. Manual movement is difficult, time-consuming, and inefficient, and may result in mechanical damage, deformation, or contamination of the material. Handling without mechanical support not only wastes time but also creates a real risk of worker injury.
- Friction and adhesion to surfaces
Coated PVC surfaces often “stick” to the working table, making the material feel even heavier and making precise positioning before welding or cutting difficult.
- Safety and ergonomics
Manually dragging heavy sheets with several workers leads to strain, tendon and muscle injuries, and back problems. This increases sick leave, absenteeism, and even staff turnover.
- Positioning precision
Even a few millimeters of misalignment can cause leakage in the finished product. In many cases, 6–7 people are needed just to position a single sheet — a costly use of time and labor that directly affects efficiency and profitability.
Possible Technological Solutions
- High-Frequency (HF) Welding Machines — Fiab HPS MINI and HPS Q-Drive
With Fiab HPS MINI and HPS Q-Drive, there is no need to struggle with moving the material. Designed specifically for efficient handling of large-format PVC sheets, these machines allow a single operator to guide the welder to the right spot and start welding at the push of a button. (See HPS Q-Drive on YouTube.)
- Air flotation tables
Create an “air cushion” beneath the material, lifting it slightly and drastically reducing friction, enabling smooth and precise movement of even the largest sheets.
- Roller tables and guide systems
Crosswise and longitudinal rollers make material handling and precise positioning much easier.
- Vacuum lifters and suction systems
Allow safe lifting and moving of sheets without bending or deforming their structure.
- Automation and robotics
Integration with industrial robots and manipulators eliminates manual handling and boosts production efficiency.
Why Invest in Ergonomics and Automation?
- Higher productivity
Shorter production cycles and fewer stoppages.
- Fewer errors and waste
Lower risk of material damage, more precise welds, and fewer customer complaints.
- Workforce safety
Less physical strain and lower injury risk, leading to reduced turnover.
- Better product quality
Strong, repeatable welds with consistent durability.
- Lower long-term costs
Less manual labor = reduced personnel costs and higher employee retention.
Handling large PVC sheets is demanding — but it doesn’t have to be problematic. With modern solutions such as HF welding machines (Fiab HPS MINI and HPS Q-Drive), air flotation tables, or automated positioning systems, production can be made significantly simpler and faster.
Invest in ergonomics, safety, and efficiency. Contact us — we’ll help you choose the right solution for your production.
