A heavy-duty crane is the central lifting device when very large components, steel structures, bridge segments, or massive concrete elements must be moved, set, or deconstructed safely. In many projects it serves as the logistical backbone: it lifts, holds, rotates, and positions components while separating tools such as concrete pulverizers, combination shears, or hydraulic rock and concrete splitters perform the actual separation. This enables workflows in concrete demolition, strip-out, special demolition as well as in rock excavation and tunnel construction to be controlled precisely and with low vibration.
Definition: What is meant by heavy-duty crane
A heavy-duty crane is a crane with high load-bearing capacity for large load moments and radii. It is engineered to lift or travel with loads from the double-digit up to the four-digit ton range safely. Typical are high-performance boom and mast systems (telescopic or lattice), extensive ballast, precise controls, and comprehensive load-moment limiters. In building construction, industry, infrastructure projects as well as in deconstruction and special demolition, the heavy-duty crane is used to move large concrete and steel components in a controlled manner, often in close interaction with hydraulic cutting and splitting tools.
Design, components, and operating principle
Heavy-duty cranes consist of chassis or undercarriage, slewing platform, boom and mast system, hoists, stays, ropes, sheaves, hook blocks, and ballast. Outriggers and outrigger mats distribute the forces into the ground. The load moment results from load weight and radius; this yields the load charts that govern crane operation. Modern systems actively limit movements when permissible moments are reached, thereby increasing operational safety.
Capacity, radius, and lifting height
Key parameters are load-bearing capacity, maximum lifting height, radius, setup configuration, and permissible wind speeds. For deconstruction works, it is often not the maximum load that is decisive, but the usable capacity at large radii to pick components over obstacles or lift over roofs in tight city centers.
Load charts and work-area limitation
Load charts define the permissible load for each radius and configuration (ballast, boom configuration, outrigger spread). Work-area limits, anti-collision and anemometer systems support safe operation, especially when separation work with concrete pulverizers or stone and concrete splitters is carried out in parallel.
Types and typical applications
Heavy-duty cranes come in different types that have advantages and disadvantages depending on the site environment.
- Crawler cranes: very high load moments, good off-road mobility, can travel with load (depending on model and case), proven for large assemblies, bridges, and heavy deconstruction units.
- Mobile cranes (all-terrain): flexible, fast setup times, economical for changing locations, often used in urban special demolition.
- Lattice-boom large cranes and ring cranes: top class for extreme loads and radii on mega projects.
- Portals and gantry systems: stationary heavy-lift solutions with spreader beams, suitable for segmental lifting, e.g., in halls or at tunnel portals.
- Floating cranes: for lifts on and over water, e.g., for bridge or quay works.
Use of heavy-duty cranes in concrete demolition and special demolition
In controlled demolition, massive components are often first made load-free, then taken up, secured, and lowered in a controlled manner by the heavy-duty crane. In this sequence, separating tools intervene: concrete pulverizers cut reinforcement and remaining concrete webs, stone and concrete splitters create defined intended fracture lines with low vibration. Combination shears, Multi Cutters, and steel shears separate sections, beams, and tanks while the crane carries the loads and secures load paths.
Separating, securing, lowering
The combination of crane-held support and local separation reduces uncontrolled fracture patterns. Spreader beams, rigging gear, and lifting points are chosen so that pull directions align with the planned cut or split joints. This allows large floor slab fields or wall panels to be cleanly lifted out and further processed on the ground.
Cut guidance and sequence planning
For thicker components, work is often performed in multiple layers: pre-drill, set splitting cylinders, apply concrete pulverizers to the remaining cross-sections, then lift out with minimal deflection. Multi Cutters and steel shears accelerate the separation of reinforcement cages or hollow sections, especially in composite construction.
Power packs and auxiliary equipment
Hydraulic power units for cranes supply crane-near tools with energy when on-site connections are limited. In this way, concrete pulverizers, combination shears, or stone splitting cylinders can be operated at exposed locations that are accessible only by crane. The crane acts as a positioning aid and safety reserve.
Rock excavation, tunnel construction, and natural stone extraction
In rock and tunnel projects, heavy-duty cranes are used to move heavy equipment, formwork, segments, or rock blocks. Stone splitting cylinders and stone and concrete splitters enable low-vibration solutions in combination with the crane when blasting is excluded. In natural stone extraction, opened blocks can be safely lifted and loaded with spreader systems after splitting.
Lifting accessories, rigging, and add-on equipment
The choice of lifting accessories is crucial for safety and efficiency. Rigging gear and spreader beams must match the geometry of the component, the cut joints, and the tool engagement points.
- Spreader beams and spreader bars to reduce sling angles and to lift large-area elements gently.
- Shackles, chain and textile slings with certified capacities, matched to the crane’s load chart.
- Gripping and clamping systems for special geometries; for concrete and masonry often in conjunction with concrete pulverizers or with preparation by splitting techniques.
- Catching and safety nets or secondary safeguards where components may give way during separation.
Planning, logistics, and site organization
A heavy-lift plan considers load-bearing capacity, configuration, load path, ground parameters, and traffic management. In urban deconstruction, work windows, noise and emission requirements, and coordination with cutting and splitting operations are decisive.
Capacity verification and subsoil
Outrigger pressures are introduced into the subsoil via mats and steel plates. A robust verification of the ground and outrigger spread is central, especially at high load moments.
Weather and operating limits
Wind, temperature, and visibility influence lift permissions. The crane’s limits must be observed; work with concrete pulverizers, combination shears, or splitters is coupled to them so that cutting or splitting does not occur in critical ranges.
Communication and visibility
Briefing, unambiguous signals, radio discipline, and clear responsibilities are to be defined. Lines of sight between crane operator, rigger, and the operators of the hydraulic tools must be ensured.
Risk assessment and occupational safety
Heavy lifts require technical and organizational measures: secured exclusion zones, redundant lifting points where reinforcement is unknown, conservative load assumptions, and regular inspection of rigging gear. Separation work is planned so that no uncontrolled constraints arise. Notes on obligations, inspection intervals, and suitability of the parties involved must be observed per the applicable regulations without anticipating the specifics of each case.
Practice-oriented scenarios from the application areas
In inner-city special demolition, a heavy-duty crane can lift slab panels over the roof while concrete pulverizers separate remaining webs. In strip-out and cutting of industrial plants, the crane supports the controlled lowering of segments previously separated with combination shears, Multi Cutters, or steel shears. In bridge deconstruction, spans are pre-tensioned, reinforcement is selectively opened, and the spans are then lifted out; in addition, stone and concrete splitters can be used for crack-controlled partitioning.
Selection criteria for the appropriate heavy-duty crane
The crane selection derives from load, geometry, radius, site access, and setup effort. Interfaces to tools and work sequences also matter.
- Load and radius spectrum with safety reserves, aligned to load charts.
- Setup time, ballast logistics, required setup area, and ground load-bearing capacity.
- Compatibility with spreader beams, rigging gear, and crane-near use of hydraulic power packs.
- Ambient conditions: noise and vibration limits, work windows, neighbor protection.
Tools and systems of Darda GmbH in combination with heavy-duty cranes
Heavy-duty cranes unlock their potential as a team with precise cutting and splitting tools. Systems from Darda GmbH offer a differentiated tool palette for concrete, steel, and composite components that can be used near the crane.
Concrete pulverizers for controlled component separation
Concrete pulverizers separate concrete cross-sections and create the prerequisite for the safe lifting of large elements. In combination with spreader beams, panels can be gripped so that the pulverizer and crane do not interfere with each other. The pulverizer cuts remaining webs, the crane takes over portions of the weight and prevents spalling.
Stone and concrete splitters for vibration-sensitive tasks
Stone and concrete splitters create defined split cracks without percussive or blasting vibrations. The heavy-duty crane holds the component in position, limits movement, and allows safe removal in sections—helpful at hospitals, laboratories, or landmarked neighboring buildings.
Combination shears, Multi Cutters, and steel shears in steel and composite deconstruction
Combination shears combine cutting and pressing functions, Multi Cutters and steel shears process sections, beams, and reinforcement. The crane stabilizes components, prevents the cutting assemblies from jamming, and enables horizon-free separation even at great height.
Tank cutters for special operations
In special operations such as the deconstruction of vessels and tanks, holding and rotating by the crane is essential. Tank cutters segment the shell surface while the crane carries the load in a controlled manner and transfers placed segments in an orderly fashion.
Sustainability and emissions in heavy lifting
Purposefully combining heavy lifts with splitting and shear technology reduces noise, dust, and vibration. Less impact energy, fewer uncontrolled fractures, and shorter setup and cutting times have a positive effect on emissions and the site environment. Planning that treats lifting and separating as a single unit is the key here.