Germany is undertaking one of its largest bridge modernization projects with the replacement of the Rader High Bridge, the country’s second-longest road bridge. This significant construction effort involves 18 Liebherr cranes, ranging from the 65 K.1 to the 150 EC-B, performing critical lifting tasks. Some of these cranes are even being assembled in the water, showcasing the complexity and scale of this operation.
Located along Germany’s A7 motorway, the Rader High Bridge is a crucial traffic link from Hamburg to Denmark and the Scandinavian peninsula. Built in 1972, the bridge spans the Kiel Canal and measures nearly 1,500 meters in length. Due to heavy traffic and the bridge nearing the end of its lifespan, a replacement and lane widening have become necessary.
The project is supported by Friedrich Niemann GmbH & Co. KG’s rental fleet, providing robust crane support. On-site are five fast-erecting cranes, including two 65 K.1s and three 81 K.1s, assisting with the foundational work. Additionally, six 125 EC-B and seven 150 EC-B flat-top cranes are aiding in the construction of the new bridge piers. These cranes are performing under challenging conditions, with high wind speeds presenting significant hurdles for both the machines and the construction crew.
One of the initial cranes, a 125 EC-B, was assembled in late 2023 on the pile cap of the first bridge pier in Lake Borgstedt. A Liebherr LR 1250 crawler crane, placed on a floating platform, facilitated this assembly. This setup required precise planning due to the restricted permissible hook height of the crawler crane. The flat-top crane was assembled at a height of 30 meters before climbing to a final height of 50 meters using hydraulic climbing equipment. This elevated position allowed it to operate 15 meters above the roadway.
Another crane, a 150 EC-B 8 Litronic, initially worked on land but needed relocation as the project advanced. In June 2024, it was moved to a new position in the water using a ferry and a 220-tonne crawler crane. Once reassembled, it climbed to a height of 50 meters, boasting a jib length of 40 meters and a lifting capacity of up to eight tonnes.
The intricate planning and execution of these crane operations were supported by Liebherr’s Tower Crane Solutions project department. Their expertise was crucial in managing the cranes’ assemblies on floating platforms and ensuring the structures avoided collisions with the newly erected piers. Additionally, wind conditions had to be meticulously factored into the static calculations, as high winds could lead to partial or full closures of the bridge.
The Rader High Bridge’s replacement is being conducted in two stages, with traffic continuing to flow across the existing structure and the Kiel Canal. The first phase, involving the construction of the eastern half of the bridge, is scheduled to complete by 2026. Following this, the old bridge will be demolished, and the western section will be built, with the entire project expected to finish by 2031. The new bridge will feature six lanes, significantly improving the traffic flow between Germany and its northern neighbors.
