WOLFF cranes constructing high bridge over Neckar Valley
Equipment

WOLFF cranes constructing high bridge over Neckar Valley

When completed, this impressive 667-m-long and up to 90-m-high bridge will span the Neckar Valley near the small town of Horb in Baden-W'rttemberg. Thanks to this new bypass, traffic in the centre of Horb will be alleviated and the region's transport infrastructure will be upgraded. But until then, there will be plenty to do for the Porr GmbH & Co. KGaA construction company and the five WOLFF cranes that are in use at the enormous construction site. Their figures are also impressive: Two freestanding WOLFF cranes are operating on 96.4- and 100.9-m-high towers " a structural challenge for the Wolffkran team.

At present, the two WOLFF 7534.16 Clear cranes are drawing a lot of attention in the Neckar Valley: Both are around 100 m high and tower over the first 70-m elements of the new viaduct. Since the fall of 2023, they have been moving heavy freestanding steel components, formwork, reinforcements, and concrete buckets. With their 75-m jibs, they can lift a maximum of 16.5 tonne and 3.4 tonne at the top (4-strand operation). "This is normally not possible with a freestanding crane," explains Wolfgang Kavelius, Sales Manager at Wolffkran GmbH. "But the special design of the bridge piers meant that no tie-ins could be used, or they would have been disproportion-ately complex and expensive."

The technical WOLFF team makes it possible For this reason, Porr turned to the technical support team at Wolffkran, which not only developed a suitable crane concept but also a special structural solution for the two Porr-owned WOLFF cranes. "To ensure the necessary stability, the towers were assembled using three different tower elements," explains Peter Hegen-bart, Head of Sales Project Engineering at Wolffkran GmbH. The lower third of the towers is formed by the TV 33 tower element with a side length of 3.3 meters. Above this is a transition area composed of tower sections with a side length of 2.5 meters, which leads into the upper half of the tower made of 2x2-meter tower sections (TV 20). ?This specialized structure makes it possible to limit the maximum tower deformation to well under two meters, thus allowing the cranes to be operated safely as freestanding units," says Hegenbart.

?Thanks to Wolffkran's experience and technical expertise, we can use our own WOLFF 7534 Clear cranes as planned. This also allowed us to simply rent the additional 3.3-meter tower elements we needed for the project. We appreciate this flexibility, which goes above and beyond the normal standard, from our long-standing part-ner Wolffkran," says Markus Jahn, Project Manager at Porr.

Two-stage assembly in the narrow Neckar Valley In the inaccessible terrain of the Neckar Valley, which is also trav-ersed by an ICE railway line and a cycle path, the available space is very limited, which makes the construction site logistics particularly challenging. Because it was not possible to use a sufficiently large mobile crane to erect the two WOLFF 7534.16 Clear cranes to their ultimate heights, the assembly was carried out in two stages. After the mobile crane had assembled the tower to a height of around 60 meters, the cranes climbed the remaining 40 meters to the top using an external climbing mechanism. For space reasons, both cranes were placed on foundation anchors. As construction progresses, the complex assembly process, which takes two days per crane, will have to be repeated, as one of the two cranes will be moved to follow the progress of the expanding bridge.

The WOLFF 7534.16 Clear are currently being supported by a WOLFF 6031.12 Clear with a 65-meter jib and a 47.3-meter hook height. As the construction process moves forward, a WOLFF 7534.16 Clear and a WOLFF 6031.12 Clear from the Porr crane fleet will support the pack.

When completed, this impressive 667-m-long and up to 90-m-high bridge will span the Neckar Valley near the small town of Horb in Baden-W'rttemberg. Thanks to this new bypass, traffic in the centre of Horb will be alleviated and the region's transport infrastructure will be upgraded. But until then, there will be plenty to do for the Porr GmbH & Co. KGaA construction company and the five WOLFF cranes that are in use at the enormous construction site. Their figures are also impressive: Two freestanding WOLFF cranes are operating on 96.4- and 100.9-m-high towers a structural challenge for the Wolffkran team. At present, the two WOLFF 7534.16 Clear cranes are drawing a lot of attention in the Neckar Valley: Both are around 100 m high and tower over the first 70-m elements of the new viaduct. Since the fall of 2023, they have been moving heavy freestanding steel components, formwork, reinforcements, and concrete buckets. With their 75-m jibs, they can lift a maximum of 16.5 tonne and 3.4 tonne at the top (4-strand operation). This is normally not possible with a freestanding crane, explains Wolfgang Kavelius, Sales Manager at Wolffkran GmbH. But the special design of the bridge piers meant that no tie-ins could be used, or they would have been disproportion-ately complex and expensive. The technical WOLFF team makes it possible For this reason, Porr turned to the technical support team at Wolffkran, which not only developed a suitable crane concept but also a special structural solution for the two Porr-owned WOLFF cranes. To ensure the necessary stability, the towers were assembled using three different tower elements, explains Peter Hegen-bart, Head of Sales Project Engineering at Wolffkran GmbH. The lower third of the towers is formed by the TV 33 tower element with a side length of 3.3 meters. Above this is a transition area composed of tower sections with a side length of 2.5 meters, which leads into the upper half of the tower made of 2x2-meter tower sections (TV 20). ?This specialized structure makes it possible to limit the maximum tower deformation to well under two meters, thus allowing the cranes to be operated safely as freestanding units, says Hegenbart. ?Thanks to Wolffkran's experience and technical expertise, we can use our own WOLFF 7534 Clear cranes as planned. This also allowed us to simply rent the additional 3.3-meter tower elements we needed for the project. We appreciate this flexibility, which goes above and beyond the normal standard, from our long-standing part-ner Wolffkran, says Markus Jahn, Project Manager at Porr. Two-stage assembly in the narrow Neckar Valley In the inaccessible terrain of the Neckar Valley, which is also trav-ersed by an ICE railway line and a cycle path, the available space is very limited, which makes the construction site logistics particularly challenging. Because it was not possible to use a sufficiently large mobile crane to erect the two WOLFF 7534.16 Clear cranes to their ultimate heights, the assembly was carried out in two stages. After the mobile crane had assembled the tower to a height of around 60 meters, the cranes climbed the remaining 40 meters to the top using an external climbing mechanism. For space reasons, both cranes were placed on foundation anchors. As construction progresses, the complex assembly process, which takes two days per crane, will have to be repeated, as one of the two cranes will be moved to follow the progress of the expanding bridge. The WOLFF 7534.16 Clear are currently being supported by a WOLFF 6031.12 Clear with a 65-meter jib and a 47.3-meter hook height. As the construction process moves forward, a WOLFF 7534.16 Clear and a WOLFF 6031.12 Clear from the Porr crane fleet will support the pack.

Next Story
Infrastructure Urban

ICMM CEO Rohitesh Dhawan Visits Hindustan Zinc

Hindustan Zinc, India’s only and the world’s largest integrated zinc producer, hosted Rohitesh Dhawan, President & CEO of the International Council on Mining and Metals (ICMM), at its flagship Sindesar Khurd Mine (SKM) in Rajasthan. The visit follows Hindustan Zinc’s induction as the first Indian company into ICMM, marking a significant milestone for India’s mining sector on the global sustainability stage.Dhawan, accompanied by run Misra, CEO of Hindustan Zinc, and the senior leadership team, toured Sindesar Khurd Mine – the world’s fourth-largest silver-producing mine – to ..

Next Story
Infrastructure Urban

Amit Gupta Appointed CFO of Vedanta Jharsuguda Unit

Vedanta Aluminium has announced the appointment of Amit Gupta as Deputy Chief Financial Officer of its aluminium business and Chief Financial Officer of its Jharsuguda unit in Odisha.Gupta has been associated with the Vedanta Group since 2018, beginning as Group Head – FP&A at Vedanta Resources. With over two decades of cross-sector experience, he brings strong expertise in financial strategy, project finance, and business transformation.Prior to this role, he served as CFO of Bharat Aluminium Company (BALCO), where he led finance operations for more than four years. He has also held sen..

Next Story
Infrastructure Energy

Adani Power To Build 2,400 MW Plant in Bihar

Adani Power on Saturday (September 13, 2025) announced plans to set up a 2,400 MW ultra super-critical power plant in Bihar at an investment of $3 billion (around Rs 26.48 billion).The company has signed a 25-year Power Supply Agreement (PSA) with Bihar State Power Generation Company Ltd (BSPGCL) to supply electricity from the project, which will be located at Pirpainti in Bhagalpur district.The PSA follows a Letter of Award issued by BSPGCL to Adani Power on behalf of North Bihar Power Distribution Company Ltd (NBPDCL) and South Bihar Power Distribution Company Ltd (SBPDCL) in August. Adani P..

Advertisement

Subscribe to Our Newsletter

Get daily newsletters around different themes from Construction world.

STAY CONNECTED

Advertisement

Advertisement

Advertisement

Talk to us?