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WOLFF Cranes Are Constructing a High Bridge Over the Neckar Valley
Thanks to this new bypass, traffic in the center 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 5 WOLFF cranes that are in use at the enormous construction site. Their figures are also impressive: 2 freestanding WOLFF cranes are operating on 96.4- and 100.9-m-high towers – a structural challenge for the Wolffkran team. At present, the 2 WOLFF 7534.16 Clear cranes are drawing a lot of attention in the Neckar Valley. 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 t and 3.4 t at the top (4-strand operation). “This is normally not possible with a freestanding crane,” explained 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.” 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 2 WOLFF cranes. “To ensure the necessary stability, the towers were assembled using 3 different tower elements,” explained Peter Hegen-bart, head of sales Project Engineering at Wolffkran GmbH. “This specialized structure makes it possible to limit the maximum tower deformation to well under 2 m, thus allowing the cranes to be operated safely as freestanding units,” he said. “Thanks to Wolffkran’s experience and technical expertise, we can use our own WOLFF 7534 Clear cranes as planned. This also al-lowed us to simply rent the additional 3.3-m 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,” said Markus Jahn, project manager at Porr GmbH. In the inaccessible terrain of the Neckar Valley, which is also traversed 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 2 WOLFF 7534.16 Clear cranes to their ultimate heights, the assembly was carried out in 2 stages. After the mobile crane had assembled the tower to a height of around 60 m, the cranes climbed the remaining 40 m 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 2 days per crane, will have to be repeated, as one of the 2 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-m jib and a 47.3-m 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.
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The lower third of the towers is formed by the TV 33 tower element with a side length of 3.3 m. Above this is a transition area composed of tower sections with a side length of 2.5 m, which leads into the upper half of the tower made of TV 20 2x2-m tower sections. 
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