Liebherr has introduced an innovative approach for handling ballast on its 2,500-tonne LR 12500-1.0 crawler crane, using Self-Propelled Modular Transporters (SPMTs) as a versatile and mobile ballast wagon. This advancement aims to simplify and enhance crane operations by enabling the crane to control SPMTs directly, a first for the industry. This new method eliminates the need for auxiliary cranes and extra personnel, offering a solution that accelerates setup and teardown times on heavy-duty construction sites.
The ballast wagon, essential for maintaining stability during crane lifts, typically requires intricate setup with suspended counterweights. Traditionally, operators needed to stack and unstack counterweights, often with the assistance of an additional crane, which could be time-consuming and costly. Liebherr’s approach allows the crane to carry all the ballast it requires upfront, adjusting dynamically as needed without requiring auxiliary support. This streamlining translates into both time and resource savings on complex lifting jobs, where efficiency and precision are paramount.
While the idea of employing SPMTs for ballast isn’t entirely new—Liebherr had previously tested similar configurations with its LR 11000 model—the direct integration of the SPMTs into the crane’s control system represents a significant technological leap. Previously, operating SPMTs alongside cranes necessitated a separate team to manage the transporters, coordinating movements with the crane operator. This arrangement, while effective, introduced additional layers of communication and potential for delays. Now, the LR 12500-1.0 can control the SPMTs directly, mimicking a traditional ballast wagon but with far more flexibility.
To bring this concept to life, Liebherr collaborated closely with Sarens, a global leader in crane rental and heavy lifting, and KAMAG, a specialist in heavy-duty vehicle manufacturing. KAMAG developed a custom control box that links the crane’s LICCON system to the SPMT units. This integration enables the SPMTs to function as a seamless extension of the crane, following precise operator commands. The control box design leveraged the similarity between Liebherr’s LICCON control system and KAMAG’s vehicle control system, making it possible to develop a stable, integrated solution relatively swiftly.
Liebherr’s Jens Könneker, Product Manager for Crawler Cranes, emphasized the robustness of the solution, noting, “Liebherr, KAMAG, and Sarens successfully tested this system with the LR 11000, achieving full functionality in movement—circular, parallel, towing—just like a standard ballast wagon.” He explained that Liebherr has now scaled this technology to the LR 12500-1.0, a much heavier crane, offering operators the same range of movement and operational ease.
Sarens has already placed an order for this new setup, incorporating 36 SPMT axles, divided into six 6-axle units. This configuration supports a massive 1,400 tonnes of derrick ballast, allowing for adjustable ballast radii of 25, 30, and 35 meters, adding flexibility across various lift configurations.
Liebherr’s new system not only maximizes operational efficiency but also reduces the need for complex on-site reconfigurations, highlighting the growing role of automation and intelligent control in heavy-duty lifting. With its direct integration, this ballast wagon solution represents a notable step forward in the world of large-scale crane operations, setting a new standard for how crawler cranes handle ballast in challenging construction environments.
