Steel and welding constructions up to 30 t, piping construction, as well as container and apparatus construction for industry
Z.A.P. Stahlbau und Schweißfachbetrieb GmbH
LeverkusenNew on Amplifa
About ZAP GmbH
Z.A.P. Stahlbau und Schweißfachbetrieb GmbH is a family-owned business established in 1984 in Leverkusen, specializing in welding work. The company manufactures steel and welded constructions up to 30 tons, form boxes, and core meshes for the foundry industry, container and apparatus construction components, sheet metal processing, and turned parts in single and small series production. It processes steel, stainless steel, brass, and aluminum, among others, as pipes up to Ø 600 mm, sheet metal cuts from 0.5 to 100 mm, and profiles such as HEB, HEA, HEM, U-angle, and round, square, and T-steel. In addition to manufacturing, the service offering includes piping installations, plant and machinery construction, construction site deployment, repairs, spare part manufacturing according to sample or drawing, and steel trade. As an expert company according to WHG, the company also services and maintains plants used for handling water-hazardous substances. At the Leverkusen location, there is a 1000 m² assembly area and two gantry cranes with a total lifting capacity of 36 tons; customers come from the foundry, chemical, and paper industries, as well as commercial laundries.
- Site
- Leverkusen
- Processes
- Welding work, Steel and welded constructions, Piping construction / Piping installations, Sheet metal processing, Turning work, Container and apparatus construction, Form boxes and core meshes (for foundry industry), Plant and machinery construction
- Materials
- Steel, Stainless Steel, Brass, Aluminum, Pipes up to Ø 600 mm, Sheet metal cuts 0.5 – 100 mm, HEB Beams, HEA Beams
- Certificates
- EN 1090-2:2008+A1:2011, EN 1090-2
- Founded
- 1984
- Employees
- 6
- Industries
- Foundry industry, Chemical industry, Paper industry, Commercial laundries
- 01
Steel trade / Material procurement
- 02
Sheet metal processing
- 03
Turning work
- 04
Welding and construction engineering
- 05
On-site assembly
- 06
Repair and maintenance
Materials and Processes
Steel
Base material for steel constructions up to 30 t, form boxes, core meshes, and containers; available as pipes, sheets, beams, and profiles.
Stainless Steel
Used in container and apparatus construction as well as in piping construction for the chemical industry.
Brass
Processed in sheet metal processing, turning work, and welding.
Aluminum
Processed in sheet metal processing, turning work, and welding.
Structural Profiles
Rolled profiles for load-bearing steel constructions, available in steel trade.
Pipes up to Ø 600 mm
Pipe material for own piping construction and for delivery to customers.
Location
Leverkusen
DEHeadquarters with assembly hall and steel trade
- Part weight / size
- Steel constructions up to 30 t
- Lot size
- Single and small series production
- Materials
- Steel, Stainless Steel, Brass, Aluminum
- 1000 m² assembly hall
- 2 gantry cranes (Total lifting capacity 36 t)
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Welding workJoining | – | – | 30 t | Small series | Steel, Stainless Steel, Brass, Aluminum |
| Steel and welded constructionsJoining | – | – | 30 t | 1 piece (single production) – Small series | Steel |
| Piping construction / Piping installationsJoining | – | – | – | – | Steel, Stainless Steel |
| Sheet metal processingForming | – | – | – | – | Steel, Stainless Steel, Brass, Aluminum |
| Turning workMachining | – | – | – | – | Steel, Stainless Steel, Brass, Aluminum |
| Container and apparatus constructionJoining | – | – | – | – | Steel, Stainless Steel |
| Form boxes and core meshes (for foundry industry)Welding/Construction | – | – | – | – | Steel |
| Plant and machinery constructionAssembly | – | – | – | – | Steel, Stainless Steel |
| Assembly of steel constructions (construction site deployment)Assembly | – | – | – | – | Steel |
| Repair and maintenance of plants, pipelines, and steel constructions, manufacturing according toAssembly | – | – | – | – | Steel |
| Maintenance and upkeep of facilities for handling water-hazardous substances (expert companyAssembly | – | – | – | – | – |
| Steel trade (Supply of steel, pipes, sheet metal cuts, profiles)Engineering | – | – | – | – | Steel, Stainless Steel, Brass, Aluminum |
3 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Assembly Hall | – | 1 | 1000 m² assembly area | – | Leverkusen |
| Gantry Crane | – | 2 | Total lifting capacity 36 t | – | Leverkusen |
| Assembly Hall (536 m², per homepage) | – | 1 | 536 m² | – | Leverkusen |
Additional services
Quality and Certification
Manufacturing is performed by certified welders and welding specialists; the operation is certified according to EN 1090-2 by TÜV Rheinland. Additionally, approval according to §20 Radiation Protection Ordinance and expert business status according to WHG exists.
| Evidence | Leverkusen |
|---|---|
| EN 1090-2 |
History
- 1984
Founded as a piping construction and welding specialist company; focus on piping installations in the chemical industry, paper industry, and commercial laundries.
- 2010
Reorganization on 01.01.2010 into Z.A.P. Stahlbau und Schweißfachbetrieb due to the increased share of specialized welding work and steel constructions for the foundry industry.