New crawler cranes drive heavy lifting progress in global infrastructure

Crawler cranes are known for their stability, pick and carry ability and heavy lifting capacity, and are widely used in large scale construction, energy, and infrastructure projects, making them a key investment for contractors. Manufacturers have launched several new models this year already, with more expected following the big German construction trade show Bauma, taking place this month.

Liebherr crawlers stabilising the ground for a new roadway in Utah, USA. (Photo: Liebherr)

Crawlers are popular worldwide and there has been an increase in use in the USA in particular. Specialist forecaster Off Highway Research managing director Chris Sleight says crawler crane sales in North America remained strong in 2024, defying a broader slowdown in the construction equipment market.

“Crane sales in the USA continued to rise in 2024, despite a slowing growth in the construction market and falling sales of other types of construction equipment,” Sleight comments. “While high-volume machinery like mini excavators and compact tracked loaders were affected by a housing market reset, cranes benefited from steady infrastructure and non-residential building projects.”

New models

With that in mind, several crane manufacturers have launched new crawlers, with some timing their latest launches with the big construction trade show Bauma.

Sennebogen in Germany has expanded its telescopic boom crawler crane range upwards with a new top model, the 6203 E, which has a 200 tonne lifting capacity and a 78 metre maximum reach.

Sennebogen’s new 200 tonne capacity 6203 E crawler. (Photo: Sennebogen)

Designed for heavy precast concrete construction, bridge and infrastructure projects, and wind turbine maintenance, it is the tenth model in Sennebogen’s telescopic crane lineup.

The six section pinned boom extends to 56.4 metres, with a pinning point at 90 per cent extension to enhance rigidity and lifting performance. An optional hydraulically adjustable jib extends the reach to 78 metres, while 16 preset extend modes simplify boom adjustment, saving time during reconfiguration.

Pick and carry

At short boom lengths, on uneven ground and in pick and carry operation, the new crane has lifting charts for lifting out of level at up to 4 degrees. For pick and carry duty it can travel with 100 % of the specified load capacity on the hook and can slew those loads through 360 degrees.

Maximum track width of the undercarriage is 6 metres which can be reduced hydraulically to a minimum of 3.5 metres. Transport width is 3 metres, without the crawler tracks, and it can be moved in seven loads.

Power for the 6203 E is from a194 kW EU Stage V diesel engine. As with the other Sennebogen models with Stage V emissions standard engines, this latest one can be fuelled by HVO (hydrogenated vegetable oil).

The hydraulic winches each offer a maximum line pull of 135 kN and a rope speed up to 115 m/min.

Sennebogen maintains a ‘keep it simple’ design philosophy, using hydraulics and electrics where beneficial, while ensuring easy access to service points for faster maintenance.

Managing director Erich Sennebogen highlighted the growing demand for large telescopic crawler cranes, stating, “To meet this demand, we are now expanding our range significantly upwards with the new 200 tonne crane.”

The 6203 E gets its first public airing at Bauma 2025.

Big lift

Manufacturer Manitowoc has introduced its largest Grove Hydraulic Crawler (GHC) crane to date, the GHC200, expanding its telescoping crawler lineup with increased lifting capacity and reach. The new model, which has a 160 tonne (200 US ton) capacity and a 56.4 metre main boom, is designed to handle heavy lifts in challenging environments, including swampy or mountainous terrain.

Manitowoc’s largest Grove Hydraulic Crawler (GHC) crane to date, the GHC200. (Photo: Manitowoc)

The GHC200, built by Sennebogen in Germany, was first presented to dealers and customers at Manitowoc’s Crane Days event in May 2024 at the company’s Shady Grove facility in Pennsylvania.

According to JJ Grace, product manager for GHC cranes, the demand for higher load charts continues to grow as job sites become more complex. “The GHC200 provides increased lifting capacity, making it well-suited for projects in general construction and renewable energy,” Grace says.

The crane has an additional 90 % pinning location on the boom sections, allowing for increased capacity and flexibility when setting up. With the 21.8 metre manual or hydraulic swingaway extension, it reaches a maximum tip height of 81 metres. Designed for manoeuvrability, the GHC200 offers pick and carry capabilities at 100 % of its load chart on inclinations up to 4 degrees and full 360 degree swing capacity.

For transport, the crane can be delivered to a job site in six to seven loads and features a self-assembly system for efficient setup. Inside the cab, operators will find an air suspension heated seat, climate control, and integrated cameras providing hoist, rear and right side views. The 20 degree tilting cab is designed to improve visibility and operator comfort when working at steep angles with an extended boom.

Green drive

Among other new cranes Liebherr will unveil a battery electric version of its 300 tonne capacity LR 1300 SX crawler crane at Bauma. (Photo: Liebherr)

Liebherr will unveil a battery-electric version of its 300 tonne capacity LR 1300 SX crawler crane at Bauma 2025, marking what the manufacturer says is a significant step towards sustainable lifting solutions. Battery drive technology will be shown on the lattice boom crawler crane. It will be shown for the first time as a battery-electric version with zero emissions. It features a 438 kW electric motor powered by a 392 kWh battery, enabling up to 13 hours of operation on a single charge, depending on the application, Liebherr says.

Designed for zero emission lifting, the crane offers the same performance as its diesel powered counterpart while reducing environmental impact. Liebherr says its battery drive technology will support industries transitioning to cleaner energy sources without compromising lifting capacity or efficiency.

Fleet additions

Bigge Crane and Rigging Co. in the USA has expanded its fleet with the addition of multiple Liebherr crawler cranes. The company, which already operates nearly 200 Liebherr cranes, has added several new models to support infrastructure, industrial, and heavy lift projects across North America.

The latest acquisitions include 14 Liebherr LR 1300.1 SX crawler cranes, 8 Liebherr LTR 1220 telecrawlers, 4 Liebherr LR 1500 crawler cranes and 2 Liebherr LR 1700 crawler cranes.

The expansion comes as the construction industry anticipates increased demand for heavy-lifting equipment.

Elsewhere in the USA, two Liebherr HS 8100 HD duty cycle crawler cranes were used by Densification, Inc. for soil stabilisation on the US-191 Realignment Project near Vernal, Utah in the USA.

This project aims to replace 4.2 kilometers of steep switchbacks with a safer, more gradual roadway.

The cranes performed dynamic compaction by dropping heavy weights to stabilise the ground, with the automated winch system ensuring precise drops. Each crane dropped 18 tonne weights from 21 metres to compact the ground, followed by 11 tonne weights from 6 metres for final surface stabilisation. The project site, with a 152 metre elevation change, posed challenges, but a custom load chart developed with Liebherr ensured safe operation on the sloped terrain.

Bigge has added new crawlers to its fleet to meet industry demands.

Robert Shaffer, vice president of Densification, Inc., says that the Liebherr cranes’ reliability and performance were crucial in keeping the project on schedule.

Back into action

Universal Cranes put its recently acquired 1,200 tonne capacity Liebherr telescopic boom crawler crane straight to work on a project to modernise a railway crossing.

The company in Australia bought the previously enjoyed LTR 11200 after full refurbishment by Liebherr in Germany. Universal wanted a big crane that was quick to set up and could be used for short term projects.

“We have realised that our customers need to lift ever larger and heavier loads on casual short-term hires and with ability to relocate on sites without derigging the crane. With the new, versatile crane, we can handle these applications in a wide range of sectors – from infrastructure to industrial projects,” explains Mark Happer, Universal Cranes general manager.

Ben Smith, national operations manager at Universal Cranes, added, “With the LTR 11200, we can move the crane fully equipped on construction sites with steep terrain. The pedestal mode also allows us to carry out jobs without having to take the crawlers to the construction site.”

The LTR 11200 has a 100 metre telescopic boom which is still claimed as the longest in the world. Other features include the Y-guy capacity enhancement system and lattice extensions for more reach. It was initially designed to assemble wind turbines.

Smith says he was happy to buy a refurbished crane from Liebherr because the work is done with great care and stands for the same high quality as found on new cranes.

There is a rise in popularity of refurbished models, a sustainable practice driven by its cost effectiveness.

Manitowoc says that its success in 2024 was largely driven by growth in its aftermarket business and refurbished crane sales, which generated a record $629.1 million in revenue. This marked a 67 % increase compared to 2020, prior to the launch of its Cranes+50 strategy. The company continues to focus on expanding non-new machine sales, with recent moves including acquiring distribution rights for the Carolinas and Georgia to strengthen its aftermarket footprint.

As Aaron Ravenscroft, president and CEO, says, “Looking ahead, Manitowoc remains focused on continuing to grow our non-new machine sales.”

Refurbished Manitowoc MLC300 VPC-Max crawler crane. Refurbished cranes are proving popular. (Photo: Manitowoc)

Strong foundation

Japanese manufacturer Kobelco Construction Machinery launched the TKE750G, a new 75 tonne maximum lifting capacity telescopic boom crawler crane at the start of this year.

Kobelco TK750G from 2017. Both this and the new TKE750G lift 75 tonnes. (Photo: Kobelco)

Powered by an EU Stage V-compliant Mercedes-Benz E9H01 engine, the crane delivers 254 kW of power, ensuring enhanced hydraulic performance, particularly for foundation works. The crane follows the design concept of Kobelco’s G series lattice boom cranes, providing high reliability, durability, and ease of operation, the company says.

Its boom length ranges from 10 to 30.1 metres, with a strong, lightweight 4 plate box structural boom designed specifically for foundation applications. The TKE750G is built for tasks such as vibration hammering, auger drilling, and hammer-grab foundation methods. It features a 7 tonne rated line pull and 22 millimetre wire rope for better performance, even on compact job sites.

In addition to its robust features, the crane has Kobelco’s KCross remote observation system, which tracks working conditions, locations, and maintenance history. The crane will be available from mid-2024.

For its domestic market Kobelco launched the 75 tonne capacity TK750G in 2017. It is a heavy duty crane suitable for piling support and auger work. Along the same lines, the new model for Europe, with the ‘E’ in its nomenclature, has a larger more powerful engine, shorter boom, stronger winches and thicker rope.

Show stoppers

Japanese manufacturer Tadano is likely to showcase a big new lattice boom crawler crane at Bauma and Sumitomo Heavy Industries Construction Cranes Co., Ltd. (HSC), also from Japan, will again share a booth with Link-Belt Cranes at Bauma. On show there will be two lattice boom crawler cranes, the 100 tonne capacity SCX1000A-3 and the 275 tonne capacity SCX2800A-3, both of which have engines to meet the EU Stage V exhaust emission regulations.

Space crawler

A Liebherr crawler and Modulift spreader beams lifted the contraction cone into place.

Designed to support human exploration and science missions returning from the Moon and Mars, the Flight Dynamics Research Facility in Hampton, Virginia, USA, features a 37 metre vertical wind tunnel at its core.

Located at NASA’s Langley Research Centre, the wind tunnel was lifted into place by PSC Crane & Rigging, using two Modulift MOD 50 spreader beams to create a four-point lift.

“Our scope of work was to supply manpower, equipment and technical know-how to assemble all the wind tunnel equipment,” says PSC senior estimating manager Adam DeBrosse. “This included large fan assemblies, turning vane assemblies (for directing the airflow), flow screens, interior test cell and also supporting equipment within the test area.”

For the contraction cone, PSC crews offloaded and assembled it on-site, validated the interior flow surface, secured the assembly, hoisted, set in place, aligned, and anchored it. The main lifting task was the contraction cone, weighing approximately 32 tonnes, which required a test pick that was called off due to building tolerances. The piece was trimmed and reset the same day.

PSC used a Liebherr LR1300SX crawler rigged with 29 metres of main boom and 38 metres of luffing jib. The section was rigged with two 6.1 metre long Modulift 50 spreader beams and eight polyester round slings.

“The challenges […] had to be ‘timed’ so that the wind tunnel equipment could be ready to install at key hold points,” DeBrosse says.

“What we’re going to do with this facility is literally change the world,” said Clayton Turner, director of NASA Langley.