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INSTALLATION INSURANCE THAT KEEPS PROJECTS MOVING
Why On-Site Installation Insurance Matters
Metal fabrication businesses that move from the workshop to the customer’s site face a different risk profile. The moment you start installing, erecting, assembling or commissioning fabricated items on-site, your exposure expands: third-party injury, damage to the client’s property, contract works losses, hot works risks, lifting operations and working-at-height hazards can all trigger costly claims and project delays.
Insure24 helps on-site fabricators arrange the right blend of Public Liability, Employers’ Liability, Contract Works and specialist extensions - so you can meet principal contractor requirements and keep projects running smoothly.
What Does On-Site Installation & Assembly Fabrication Insurance Cover?
This page is designed for fabricators who manufacture metalwork and then install it on-site - including staircases, balustrades, structural steel elements, mezzanines, handrails, guards, ducting supports, platforms, frames, gates, barriers, pipe racks, enclosures and bespoke assemblies.
Depending on your contracts, site conditions and the type of fabrication you install, your insurance should typically be tailored around the following covers:
- Public Liability – injury and property damage claims arising from your on-site works
- Products Liability – claims arising after handover, if installed metalwork causes injury or damage
- Employers’ Liability – legal requirement if you employ staff (including labour-only where applicable)
- Contract Works – damage to the works in progress, fabricated items on-site, and materials awaiting installation
- Tools, Plant & Equipment – theft, loss or damage to tools (hand tools and specialist equipment)
- Hired-in Plant – cover for equipment you hire (e.g., MEWPs, forklifts, welders, generators)
- Own Plant – cover for your own on-site plant and portable machinery
- Goods in Transit – protection for fabricated items in transit to and from sites
- Hot Works Risk – welding, cutting, grinding and associated fire risks (subject to controls)
- Working at Height & Erection – liability exposures when installing overhead/raised structures
- Lifting Operations – risks linked to cranes, slings, rigging and positioning steelwork/assemblies
- Defective Workmanship / Rectification – optional extensions may help with certain re-work costs (limited & underwritten)
- Professional Indemnity – if you provide design input, calculations, drawings, tolerances or method statements
- Business Interruption – covers loss of income following insured events that stop work (often linked to property/machinery)
- Legal Expenses – support with disputes, HSE investigations and employment issues (optional)
- Cyber & Data – if you rely on CAD/CAM, project files, CNC programs, client drawings and remote access (optional)
Common Risks for Fabricators Installing On-Site
Workshop-only fabrication risks are significant - but installation introduces site hazards and contractual obligations that can quickly turn a minor incident into a major claim. Below are common claim triggers we see for on-site installation and assembly work.
- Damage to client property – sparks, heat, impact or dropped items damaging floors, walls, machinery or finished areas
- Injury to third parties – visitors or other trades injured by tools, sharp edges, unsecured materials, trip hazards
- Hot works fire – welding/cutting leading to ignition within cavities, insulation, roof spaces or plant rooms
- Working at height incidents – falls, dropped objects, scaffold/Mewp usage, unsafe access platforms
- Lifting & rigging failures – incorrect slinging, load shift, crane movement, contact with structures or services
- Contract works damage – fabricated items damaged on site before handover (impact, weather, theft, vandalism)
- Theft of tools – tools stolen from vans, site cabins, welfare areas or unsecured compounds
- Delay / downtime – project stoppage from accidents, re-work, investigation or denied site access
- Defective installation allegations – items claimed to be installed incorrectly, unsafe, out-of-level or non-compliant
- Damage to services – striking electrical cables, sprinkler lines, gas pipes, compressed air or data cabling
- Weather exposure – wind or rain damaging temporary works, unfinished structures or stored materials
- Subcontractor issues – liability arising from labour-only workers or subcontractors under your supervision
- Off-site storage exposure – fabricated items held in yards/containers before delivery to site
- Transportation damage – scratching, bending or corrosion during transit for powder-coated/finished parts
- Contractual penalties – liquidated damages, rejection clauses, re-installation costs
- Site access restrictions – shutdown windows, permits-to-work, out-of-hours requirements increasing risk & cost
Why Choose Insure24 for Installation & Assembly Fabrication Cover?
Installation work sits at the crossover between fabrication, contracting and engineering services. Getting the insurance “shape” right matters: you want the correct liability triggers, appropriate contract works wording, realistic site tool limits and the right level of insurer comfort with hot works, height work and lifting operations.
- Specialist market access – insurers familiar with fabrication + installation exposures
- Contract-aware advice – support aligning cover with site requirements and contract terms
- Flexible limits – public liability, contract works and tools limits tailored to your project size
- Clear risk presentation – we help present your method statements and controls to underwriters
- Claims support – practical guidance when incidents happen on live sites
- Competitive premiums – we compare quotes and negotiate based on your risk management
- Fast turnaround – ideal when principal contractors request evidence urgently
- UK-wide cover – policies arranged for projects across England, Scotland, Wales and Northern Ireland
How to Get On-Site Installation & Assembly Fabrication Insurance
The quickest route to accurate cover is giving insurers clarity on your fabrication activities and the reality of your on-site work. Installation can mean anything from “bolting on finished handrails” to “erecting steel structures using cranes and MEWPs” - and the underwriting approach differs.
- 1. Describe your on-site work – fitting, erection, assembly, commissioning, welding, cutting, drilling, anchoring
- 2. Confirm height and access – typical max height, MEWP use, scaffolds, roof work, confined spaces (if any)
- 3. Clarify lifting operations – if you use cranes, forklifts, lifting beams, slings, rigging, appointed persons
- 4. State contract requirements – requested limits, joint names, hot works conditions, contract works sums insured
- 5. Provide values – annual turnover split, largest contract value, tools value on-site, goods in transit
- 6. Share risk controls – RAMS, permits-to-work, hot works permits, fire watches, extinguisher provisions
- 7. Review cover levels – align indemnity limits to realistic worst-case scenarios
- 8. Bind and get documents – receive evidence for principal contractors and site onboarding
Who This Insurance is For
This cover is designed for metal fabrication and engineering businesses that manufacture in-house (or manage manufacture) and then complete the installation / assembly on customer sites. Typical trades and specialisms include:
Construction & Building Installation
- Balustrades, handrails, staircases and architectural metalwork
- Gates, fencing, barriers and security installations
- Mezzanines, platforms and structural frames (non-design / design-and-build where applicable)
- Canopies, steel supports and bespoke brackets
- Fire escapes and access structures
Industrial & Manufacturing Site Work
- Machine guarding, enclosures, safety barriers
- Pipe racks, supports, frames and access walkways
- Ducting supports, plant-room steelwork, equipment skids
- Assembly line structures and mezzanine interfaces
- Maintenance welding and reinforcement works (subject to scope)
Events, Retail & Commercial Fit-Out
- Shopfront metalwork, frames and fixings
- Back-of-house steel supports and racking interfaces
- Bespoke fixtures, signage frames and mounting systems
- Temporary structures and assembly (subject to insurer appetite)
- Stainless fabrication installations for food environments
Specialist Engineering Installations
- Precision assemblies requiring alignment and commissioning
- Jig and fixture installation/anchoring
- Modifications and retrofits to existing structures
- Contract assembly of fabricated modules
- On-site measurement, drilling and finishing works
Understanding the Real Risk of On-Site Installation & Assembly
On-site installation is often where claims begin. Not because fabricators are careless - but because site conditions are variable and the consequences of an error are amplified. Finished environments, high footfall areas, integrated services, principal contractor rules and narrow shutdown windows can all increase risk.
Insurers look for evidence that you have practical site controls: competent supervision, RAMS, toolbox talks, safe access, lifting planning and hot works management. The better your controls, the more likely insurers can offer broader cover and competitive terms.
Hot Works: Welding, Cutting & Grinding
Hot works are a top cause of serious property damage claims. A small spark can travel into cavities, insulation, ceiling voids or plant rooms and smoulder for hours before ignition. Many principal contractors require hot works permits, fire watches, extinguishers and post-work checks - and insurers often apply strict conditions.
- Hot works permit systems and sign-off
- Fire watch during and after works
- Suitable extinguishers and fire blankets
- Clearance of combustibles and shielding
- Documented checks of surrounding areas/voids
Working at Height & Dropped Objects
Installation of overhead steelwork, guardrails, supports, staircases and mezzanine interfaces often requires access equipment and work above other trades. Dropped tools, fixings, offcuts or components can cause severe injury or costly damage below.
- Tool lanyards and exclusion zones
- MEWP/scaffold inspection routines
- Edge protection and fall prevention
- Competency and training records
- Safe storage of materials at height
Lifting Operations & Assembly Positioning
Even small fabricated structures can require cranes, hoists, forklifts or lifting beams. Loads can swing, shift or contact structures and services. Insurers will ask how you plan lifts, who supervises, and whether you use certified slings and competent riggers.
- Lift plans / method statements for complex lifts
- Certified slings, shackles, chains and inspection records
- Clear communication and banksman / signaller controls
- Exclusion zones and pedestrian management
- Weather consideration for outdoor lifts
Interfaces with Client Plant & Services
Fabrication installation often happens near sensitive plant: production lines, electrical panels, HVAC, sprinkler systems, gas lines or specialist equipment. A minor strike or vibration can cause operational disruption - which quickly escalates into a claim or dispute.
- Pre-start surveys and service location checks
- Permit-to-work compliance
- Isolation and lock-off procedures (where required)
- Controlled drilling and fixings
- Clear handover documentation
“The principal contractor needed higher public liability limits and contract works cover before we could start. Insure24 arranged the right policy quickly and the documents were accepted first time.”
Operations Manager, UK Metal Fabrication & InstallationHow Much Does Installation & Assembly Fabrication Insurance Cost?
The cost of cover depends on your risk profile. Insurers typically price on-site installation differently to workshop-only fabrication because frequency and severity of claims are higher on live sites.
Premiums can be influenced by contract size, working height, hot works, lifting operations, the type of environments you work in (commercial fit-out vs heavy industrial), your claims history, and the limits you require (e.g., £2m vs £5m vs £10m Public Liability).
Typical Underwriting Factors
- Annual turnover split between fabrication vs installation
- Largest single contract value and typical project size
- Maximum working height and frequency of height work
- Hot works frequency and controls (permits, fire watch)
- Use of cranes, lifting plans and competent persons
- Type of customers (domestic, commercial, industrial, public sector)
- Claims history and risk management maturity
- Tools, plant and hired-in plant values
Choosing Limits That Actually Protect You
- Public Liability: Commonly £2m–£10m (many PC’s request £5m)
- Contract Works: Should reflect the maximum value of works/materials at risk on-site
- Tools: Consider both total value and single-item limits for specialist tools
- Hired-in Plant: Match typical hire agreements and max exposure
- Employers’ Liability: Typically £10m (standard UK requirement level)
- Indemnity Period: If linking BI to property events, choose a realistic downtime period
The cheapest policy is rarely the best fit. The goal is cover that responds to real site scenarios, with limits aligned to what a “bad day” could cost.
Risk Management Tips That Can Reduce Claims (and Often Premiums)
Insurers like clear, documented controls. If you’re regularly asked to meet principal contractor standards, you may already have strong systems. Where improvements are possible, they can help reduce incidents and strengthen your insurance presentation.
Site Controls & Documentation
- RAMS tailored to each site with sign-off records
- Toolbox talks (working at height, hot works, manual handling)
- Permit-to-work compliance and documented authorisations
- Photographic surveys before and after works
- Handover pack: drawings, fixings, load ratings and compliance notes
- Quality checks: torque settings, alignment, anchor verification
Physical Controls
- Hot works shielding and removal of combustibles
- Fire watch and post-work checks
- Exclusion zones under overhead work
- Tool lanyards and controlled storage at height
- Secure tool storage: lock boxes, trackers, site cabins with robust locks
- Lift planning, competent supervision and certified rigging equipment
FREQUENTLY ASKED QUESTIONS
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What is on-site installation & assembly fabrication insurance?
It’s a tailored business insurance package for metal fabrication companies that install or assemble fabricated items on customer sites. It commonly combines Public Liability, Employers’ Liability, Products Liability, Contract Works, Tools/Plant and transit cover, with options for Professional Indemnity and additional extensions depending on your contracts and site risks.
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Do I need contract works insurance if I only install what I fabricate?
Often, yes. Contract works can cover damage to the fabricated items and materials while they are on site and before handover. Even if the project is “simple”, a dropped component, theft from site or accidental damage before completion can otherwise be uninsured.
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Does public liability cover hot works like welding and cutting?
It can, but insurers may apply conditions or require robust controls (hot works permits, fire watch, extinguishers, clearance of combustibles). The best approach is to be transparent about hot works frequency and controls so cover is arranged correctly.
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Are tools and equipment covered while on site?
Yes, if you include tools/plant cover. Policies can cover theft, loss and damage - but you’ll need suitable security (lockable storage, vans secured, site cabins locked). Limits can be tailored to reflect your tool value and specialist equipment.
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What if a fabricated item fails after installation?
Products liability (and sometimes public liability, depending on circumstances) can respond to claims for injury or property damage caused by an installed item after handover, subject to policy terms. If you also provide design input, professional indemnity may be relevant for design/specification allegations.
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Do I need professional indemnity as an installer?
If you provide drawings, calculations, design advice, tolerances, fixings specifications, or you work under design-and-build arrangements, professional indemnity is often important. It covers allegations of negligence in professional services, which standard liability insurance may not cover.
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Can I get cover for work at height and MEWP use?
Yes. Insurers will want to understand your typical max working height, frequency of height work, access equipment used (MEWPs/scaffolds) and competency controls. Clear procedures, training and inspection routines help secure better terms.
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How quickly can Insure24 arrange installation insurance?
Once we have your core details (turnover split, nature of installation work, max contract value, height/hot works/lifting exposure and claims history), we can often progress quotes quickly. If you’re starting a new site and need documents urgently, call us and we’ll prioritise your request.