Liebherr LR 1700-1.0 and LTM 1650-8.1 Execute Precision Steel Plate Lifts on Horb Neckar Valley Bridge
- Meagan Wood
- Oct 29, 2025
- 7 min read
Updated: Dec 27, 2025
30-Second Takeaway
High above Germany’s Neckar Valley, Wiesbauer GmbH & Co. KG completed one of the most technically demanding bridge lift operations in the region using a Liebherr LR 1700-1.0 crawler crane and an LTM 1650-8.1 mobile crane. Tasked with installing steel plates weighing up to 102 tonnes beneath the carriageways of the 667-metre Horb bypass bridge, the team relied on advanced Liebherr technologies including VarioTray® and V-Frame® to manage extreme loads, long radii, and confined site conditions. The project highlights how precise planning, experienced crews, and adaptable crane systems are critical to modern bridge construction.
High above the Neckar valley, an impressive project is currently under construction: as part of the new Horb bypass, the Karlsruhe Regional Council is building a 667 metre long and around 65 metre high bridge, which will carry the B32 federal road over the Neckar in future. Two Liebherr cranes from Wiesbauer GmbH & Co. KG - an LR 1700-1.0 crawler crane and an LTM 1650-8.1 mobile crane - were used to install solid steel plates on the underside of the two carriageway spans.
The demanding lifts required not only the highest precision, but also a high degree of planning and experience. The bridge over the Neckar Valley is designed as an "extra-dosed" bridge - a modern type of construction that combines elements of a cable-stayed and prestressed concrete bridge. They are characterised by their comparatively low pylons. The Horb bridge is also characterised by slender concrete footbridges, which give the bridge a graceful appearance. To ensure that these can still absorb the high bending loads, continuous steel plates are installed on the underside of the carriageways, which are firmly connected to the concrete using thousands of headed dowel pins. However, these "sheets" are by no means thin: with thicknesses of between seven and 14 centimetres and lengths of up to 157 metres, these are solid steel plates.
Heavy loads at lofty heights
Instead of welding the individual short plates onto the bridge - which would have blocked construction for weeks - they were welded into long steel plates on the ground in parallel with the other construction work, so that they could then be lifted as a whole. However, this increased the weight per element to up to 70 tonnes. To prevent the sheets from bending during lifting, they were attached to a lattice crossbeam. Including lifting gear, this resulted in loads of 85 and 102 tonnes, which had to be lifted from the valley onto the bridge being built at a height of 65 metres.
For this work, Wiesbauer used the LR 1700-1.0 with a 132 metre main boom, 12 metre fixed jib and up to 375 tonnes of ballast and the LTM 1650-8.1 with Y-guying, 155 tonnes of ballast, 16 metre telescopic extension and 38.5 metre luffing jib.
The LR 1700-1.0 was set up approximately in the centre of the valley directly in front of the bridge section where the heavier steel plates had to be mounted. This enabled the crane to cope with these loads on its own. For the positions further south, a tandem lift was necessary due to the larger radius, with the crawler crane working with the LTM 1650-8.1.
The LR 1700-1.0 first placed the 85-tonne load in an accessible position on the bridge, from where the two cranes jointly slewed it to its final position and set it down with millimetre precision.
Precise technology and millimetre-precise coordination
The combination of VarioTray and V-Frame made the LR 1700-1.0 a decisive tool in the cramped operating conditions: the ballast radius could be continuously adjusted between 13 and 21 metres, depending on the radius. With a small radius, even the small pallet of the VarioTray with 100 tonnes of ballast was sufficient in some cases.
"Without VarioTray and V-Frame, the job would not have been possible in this form," explains crane operator Ralf Paladey. "During the lift, we had to constantly adjust the ballast radius in order to maintain the exact balance."
The lift placed the highest demands on the control system and the interaction between the two machines. During the tandem lift, the working radius of the crawler crane reached up to 96 metres.
Cramped conditions and logistical challenges
The assembly of the cranes also required logistical finesse. The location was in a narrow valley - the Neckar to the north and a railway line to the south. An alternative set-up was ruled out. All the components had to be reloaded onto 8-axle low-loaders in order to safely negotiate the winding roads to the crane site in the valley.
"Even the assembly was precision work," reports Ralf Hofmann, driver of the LTM 1650-8.1. "When installing the luffing jib, we had just one metre of space to the end of the path." Positioning closer to the bridge was impossible - the projecting edge only left about one metre of clearance at the lift.
Wiesbauer had calculated various options, including the use of a more powerful crawler crane. "Our LR 11000 could have handled the load from the stand alone," says project manager Jochen Wiesbauer, "but the ballast radius would have required slewing over the river - and that wasn't possible."
A larger mobile crane was also considered, as the LTM 1650-8.1 was working at its limit. However, the dimensions of the 9-axle LTM 1750-9.1 did not allow it to travel down into the valley.
Planning with system and experience
The deployment was planned using the Liebherr tool LICCON deployment planner and a CAD system to precisely simulate all movements and loads. Nevertheless, some of the work was left to experience - especially when fine-tuning the cranes in tandem operation.
"Experience is essential here," emphasises crane operator Tim Moll. "Not everything can be calculated in advance. It is crucial to have the right sense of proportion when picking up the load and positioning the ballast pallet." After several days of intensive work, all four plates were securely mounted - a success that combined precision, technology and teamwork.
About Wiesbauer GmbH & Co. KG
Engineering-driven heavy lifting for Europe’s most demanding projects
Wiesbauer GmbH & Co. KG is one of Germany’s most respected heavy lifting, crane, and specialized transport companies, known for executing technically complex projects in infrastructure, bridge construction, energy, and industrial sectors. Headquartered in southern Germany, Wiesbauer operates nationwide and internationally, supporting projects where extreme loads, long radii, and restricted site conditions intersect.
The company operates a high-capacity fleet of Liebherr mobile and crawler cranes, including ultra-heavy crawler cranes used for bridge assembly, wind turbine installation, industrial plant construction, and large-scale infrastructure upgrades. Wiesbauer’s expertise extends beyond crane operation to include lift engineering, CAD-based planning, logistics coordination, and on-site execution.
By combining advanced digital planning tools with decades of operator experience, Wiesbauer consistently delivers millimetre-precise lifts in environments where margin for error is minimal. The Horb Neckar Valley bridge project exemplifies the company’s ability to solve complex lifting challenges through innovation, preparation, and teamwork.
Website🔗 https://www.wiesbauer.com
About Liebherr Mobile & Crawler Cranes
Advanced crane systems engineered for extreme lifting environments
Liebherr is a global leader in the development and manufacture of mobile and crawler cranes, supplying equipment for some of the world’s most challenging lifting applications. From bridge construction and wind energy to industrial plants and infrastructure megaprojects, Liebherr cranes are engineered to deliver maximum lifting performance, adaptability, and safety.
Crawler cranes like the LR 1700-1.0 are designed for long-radius, high-capacity lifts, featuring modular boom systems, advanced ballast configurations, and intelligent assistance systems. Mobile cranes such as the LTM 1650-8.1 complement these capabilities by offering flexibility, rapid deployment, and high lifting performance in confined spaces.
Key technologies including VarioTray®, V-Frame®, and LICCON control systems allow Liebherr cranes to dynamically adapt to changing site conditions, optimize stability, and reduce crane footprint requirements. Supported by a global service and engineering network, Liebherr cranes are trusted worldwide for projects where precision, reliability, and performance are non-negotiable.
Frequently Asked Questions
Why was an LR 1700-1.0 crawler crane selected for this bridge project?
The Liebherr LR 1700-1.0 was selected due to its ability to handle very heavy loads at extreme radii while maintaining stability in a confined valley environment. With steel plate assemblies weighing up to 102 tonnes and lift radii reaching 96 metres, a crawler crane with long boom capability, high ballast capacity, and precise load control was essential. The LR 1700-1.0 provided the required combination of reach, lifting power, and adaptability that smaller crawler cranes or mobile cranes could not achieve alone.
What role did the LTM 1650-8.1 play in the lifting operations?
The Liebherr LTM 1650-8.1 mobile crane was used both as a support crane and as a tandem lift partner for the crawler crane in positions where the radius exceeded the LR 1700-1.0’s optimal working range. Its Y-guying system, luffing jib, and high ballast configuration allowed it to safely share loads during complex slewing operations and fine positioning of the steel plates beneath the bridge deck.
Why were VarioTray® and V-Frame® critical to the success of this project?
The confined geography of the Neckar Valley made traditional fixed ballast configurations impossible. VarioTray® allowed Wiesbauer’s team to continuously adjust the ballast radius between 13 and 21 metres during the lift, ensuring optimal balance at every stage. V-Frame® reduced the required counterweight radius while maintaining stability, preventing the crane from slewing over restricted zones such as the river or railway. Without these systems, the crane footprint would have exceeded the available working space.
Why were the steel plates lifted as single, long assemblies instead of being installed in sections?
Installing the plates in shorter sections would have required weeks of welding work at height, significantly delaying the project and increasing safety risks. By welding the plates on the ground into sections up to 157 metres long, Wiesbauer reduced work at elevation and compressed the construction schedule. This approach, however, dramatically increased individual lift weights, making high-capacity cranes and precise lift engineering mandatory.
How was lift planning carried out for such complex tandem operations?
The lifts were planned using Liebherr’s LICCON deployment planner combined with CAD-based site simulations. Every crane movement, ballast adjustment, radius change, and slewing path was modeled in advance. However, due to the dynamic nature of tandem lifts at long radii, operator experience remained critical especially when fine-tuning load balance and coordinating crane movements in real time.
What were the biggest logistical challenges on site?
The site was constrained on both sides: the Neckar River to the north and a railway line to the south. There was no alternative crane setup location. All crane components had to be transported through narrow, winding mountain roads and reloaded onto 8-axle low-loaders. Even crane assembly required millimetre precision, with some operations allowing as little as one metre of clearance between the crane and surrounding terrain.
