Liebherr LTM 1650-8.1 Threads 33-Tonne Pipes into Holcim Cement Plant
30-Second Takeaway
A Liebherr LTM 1650-8.1 operated by Wiesbauer has installed two 33 tonne pipe sections at Holcim’s cement works in Dotternhausen, Germany. Configured with 155 tonnes of counterweight and a 42 metre luffing jib, the crane positioned the pipes at a height of 30 metres and a working radius of 39 metres. Existing pipework left only centimetres of clearance for parts of the rigging, requiring precise crane movements and close coordination between the operator and the lifting team. The installation forms part of Holcim’s KAREm exhaust gas treatment project, which combines catalytic cleaning with waste heat from the cement kiln.
Liebherr LTM 1650-8.1
Wiesbauer GmbH & Co. KG deployed its 700 tonne Liebherr LTM 1650-8.1 for a demanding pipe installation at Holcim’s Dotternhausen cement works. The operation involved two pipe sections measuring up to 38 metres long and two metres in diameter, each weighing 33 tonnes. Both had to be manoeuvred between existing installations before being positioned within the new exhaust gas treatment plant.
The challenge combined long loads, restricted clearances and an elevated installation position. Crane configuration, controlled movements and guidance from the lifting team were central to completing the work on schedule.
155 Tonnes of Counterweight and a 42-Metre Luffing Jib
The eight axle LTM 1650-8.1 is available with alternative 54 metre and 80 metre telescopic boom configurations, allowing the model to be equipped for different lifting requirements.
For the Dotternhausen operation, Wiesbauer selected a configuration using 155 tonnes of counterweight and a 42 metre luffing jib.
Wiesbauer project manager David Neher said:
“The 700-tonne crane was configured with 155 tonnes of counterweight and a 42-metre luffing jib to lift the pipes, each weighing 33 tonnes, into the plant at a height of 30 metres with a 39-metre reach.”
The crane’s rated capacity identifies its maximum lifting class. The actual operation involved handling the 33 tonne sections at the specified radius and height using the selected boom, jib and ballast arrangement.
Threading Long Loads Between Existing Pipes
The installation sequence required the team to guide the new sections beneath an existing pipeline on one side of the working area. At the tightest point, only a few centimetres remained available for the slings. Placing the second section introduced another constraint: it ran parallel to the first and had to avoid the pipe already installed.
Crane operator Ralf Hoffmann controlled the movements using Liebherr’s LICCON system, with colleague Jannik Weigle providing guidance.
Hoffmann said:
“The two pipes had to be threaded under an existing pipeline on one side. There was then only a few centimetres of space left for the slings. During the lift, the second pipe, running parallel to the first, obviously had to avoid colliding with the one already in place. Thanks to the precise LICCON control system and professional guidance from my colleague Jannik Weigle, however, it all went smoothly despite the wind.”
Both sections were installed on schedule.
Lifting Support for Holcim’s KAREm Project
The pipework forms part of a new exhaust gas treatment installation developed by Holcim and plant engineering company Scheuch. KAREm refers to the project’s objective of operating without exceptions for raw material-related emissions. According to the project account, the upgrade is intended to remove the need to rely on allowances associated with pollutants already present in the raw materials processed by the cement works.
Preparatory construction included demolishing redundant factory buildings. Some areas of the site contained basements, requiring additional support pillars before the new installation could be built. Around 2,000 tonnes of steel is being used in the plant. Other Liebherr cranes with capacities of up to 400 tonnes are supporting steel erection and plant construction.
Catalytic Treatment Using Kiln Waste Heat
The new installation combines selective catalytic reduction, or SCR, to reduce nitrogen oxides with regenerative catalytic oxidation, or RCO, to treat volatile organic compounds and carbon monoxide. The project team reports that the catalytic process operates at approximately 300°C, using waste heat available from the rotary kiln. This compares with the approximately 850°C required by the natural gas-fired thermal treatment described in the project announcement.
Conditions at Dotternhausen support this approach. Scheuch’s Georg Lechner explains that the quarry material contains relatively low levels of substances such as sulphur that could impair catalytic treatment. Its comparatively low moisture content also leaves more kiln waste heat available for the cleaning process.
The two metre pipe diameter contributes to the system’s efficiency by reducing resistance to gas flow.
Holcim project manager Michael Obermailänder said:
“The thicker the pipes, the lower the flow resistance, and the less power is needed to pump the flue gas through the pipe.”
According to the project team, using existing process heat avoids additional external fuel consumption for the catalytic treatment and the associated emissions. The wider installation also reduces cooling water requirements and supports electricity and district heating generation.
Obermailänder added:
“With the hoisting of the two pipes today, we have taken a major step towards our goals thanks to Liebherr’s technology and the Wiesbauer team.”
About Wiesbauer
Wiesbauer GmbH & Co. KG is a German heavy lifting and transport company headquartered in Bietigheim-Bissingen, Baden-Württemberg. Founded by Franz Wiesbauer in 1958, the business developed from a single mobile crane into a provider of crane services and heavy logistics.
The company’s services include mobile and crawler crane hire, heavy haulage, industrial assembly and engineering. According to the project announcement, Wiesbauer employs approximately 180 people and operates around 100 mobile and crawler cranes, with equipment extending into the 1,000 tonne class.
Its fleet is predominantly supplied by Liebherr. The combination of lifting equipment, transport and installation services enables Wiesbauer to support projects requiring coordinated movement and positioning of heavy industrial components.
Official website: www.wiesbauer-krane.de
About Liebherr
Liebherr is a family-owned equipment and technology manufacturer founded by Hans Liebherr in 1949 in Kirchdorf an der Iller, Germany. Its lifting portfolio encompasses mobile and crawler cranes, tower cranes, mobile construction cranes and maritime cranes.
Liebherr-Werk Ehingen GmbH, established in 1969, develops and manufactures telescopic and lattice boom cranes on mobile and crawler chassis. These machines serve applications including industrial installation, infrastructure construction, wind turbine erection and heavy lifting.
The manufacturer supports its equipment through technical assistance, spare parts, operator training and digital planning services. Its mobile crane technologies include LICCON controls and systems for adapting crane support and counterweight configurations to different operating conditions.
Official website: www.liebherr.com
Frequently Asked Questions
Which crane carried out the pipe installation?
Wiesbauer used a 700 tonne Liebherr LTM 1650-8.1 All Terrain crane.
How large were the pipe sections?
Each section weighed 33 tonnes and measured up to 38 metres long and two metres in diameter.
What configuration was used?
The crane was equipped with 155 tonnes of counterweight and a 42 metre luffing jib.
What made the lifts challenging?
The pipes had to pass between existing installations, with only centimetres of clearance available for the slings at one point. The second section also had to avoid the first installed pipe.
What is Holcim’s KAREm project?
KAREm is an exhaust gas treatment upgrade at the Dotternhausen cement works, combining catalytic cleaning processes with waste heat from the rotary kiln.
