Concrete is used for construction - on a large scale. The mixture of gravel, sand, cement and water is popular. It stores heat, is fire-resistant and offers great design freedom. In addition to the liquid version, which is transported to the construction site in a mixer, the flexible building material can also be produced as a prefabricated part in the factory and then installed. Prefabricated parts are particularly suitable for efficient and fast house construction; in 2017, more than nine million square meters of wall panels and 30 million square meters of ceiling panels were produced in this way. At Wöhrl Ziegel & Fertigteile, the finished parts weighing up to 16 tons must be transported undamaged from production to the external warehouse and onto the truck. For this purpose, Konecranes has designed a particularly sensitive heavy-duty forklift with robust hydraulics.

Heavy-duty forklift with flexible fork
Wöhrl manufactures floor slabs, balconies, stairs and special parts for a wide range of applications in Berghaselbach near Freising. The family business with 170 years of experience offers a portfolio of 100 different products - including bricks as well as concrete parts. A unique combination of products in Bavaria. The prefabricated parts weigh between three and 16 tons and can be up to nine meters long.

With a mast camera, the driver of the new SMV 16-1200 C heavy-duty forklift truck always has his transported goods in view. © Conecranes

"To ensure that our products arrive at the construction site undamaged, they have to be transported carefully," explains Thomas Wöhrl, Managing Director and owner. "That's why we place them on double T-beams." These are then lifted by the heavy-duty forklift truck and brought to their storage location. The forklift truck has to be very robust, because concrete dust from the plant and external storage areas accumulates and settles in the hydraulics. At the same time, sensitivity and flexibility are required: in order to fit perfectly into the beams, the forks of the heavy-duty forklift truck must be specially shaped. It must also be possible to extend the forks so that the forklift can also pick up large parts safely.

Konecranes has therefore equipped the SMV 16-1200 C heavy-duty forklift truck with a fork extension and forks with a special groove. "This means that the forks fit perfectly with the double-T beams," says Uwe Höß, Sales Manager at Konecranes Lifttrucks Germany. "The fork can be extended to a length of up to four meters and the tines can be moved individually to the left or right hydraulically." This allows the driver to pick up the double-T beams even if he doesn't approach at the perfect angle - with conventional forks, the truck has to back up and start again. The new machine with a wheelbase of 3.75 meters lifts the precast elements weighing up to 16 tons to a maximum height of four meters.

An HLL (Hydraulik Longlife) fine filter system catches the smallest particles and thus protects the hydraulics. © Conecranes

Overview thanks to camera
"When large concrete parts are stacked high, the driver must be able to maintain an overview and work precisely," emphasizes Uwe Höß. "Thanks to a camera right at the top of the mast, the driver can always see where he is steering the fork, even at a height of four meters." The truck is also equipped with an inching pedal. Uwe Höß: "If the driver steps on the brake, the travel drive is disconnected from the on-board hydraulics and the full power is available for the lifting gear." This allows the truck to maneuver safely with heavy loads.

At Wöhrl's concrete and brick plant, the hydraulics of the heavy-duty forklift truck in particular have to be robust and withstand aggressive concrete dust. The solution from Konecranes: an HLL (Hydraulik Longlife) fine filter system catches particles from three micrometers in size - more than four times finer than normal filters. This extends the oil change interval from 4,000 to up to 12,000 hours. This reduces maintenance requirements and the truck is ready for use for longer.

Lifting concrete parts in comfort
With the Optima cab from Konecranes, drivers also have a clear and pleasant working environment. The vibration- and noise-damped cab is equipped with an air-sprung seat - the latest in ergonomics. The driver can also keep an eye on the images from the mast and reversing camera at all times via a color display. as