Utilising advanced lifting technology from STAHL CraneSystems and technical implementation by Dresden Krane + Industrie Service (DKS), the new master-slave tandem crane system at DP Bahnbau Group’s Dresden Bridge workshop optimises heavy-duty assembly while ongoing operations continue uninterrupted.
Facing the heavy-duty challenge in railway infrastructure
The DB Bahnbau Group’s bridge workshop in Dresden has been a hub of concentrated expertise for nearly a century. Responsible for the repair and construction of crucial railway bridges, the site’s 100 employees manage complex infrastructure projects, including the historical restoration of the listed Chemnitz Viaduct. However, managing thousands of aging steel structures across Germany requires high-performance, ultra-reliable technology.
With intensive use and heavy loads in the main welding hall causing signs of wear and declining equipment availability, the DB Bahnbau Group needed a reliable solution to eliminate risks to long-term operational safety. To secure future productivity, the company commissioned DKS to plan a comprehensive overhaul of the system using heavy-duty crane components from STAHL CraneSystems.
Advanced technical implementation and components
The complex conversion project kicked off in November 2024, with physical dismantling and installation taking place in August 2025. Impressively, the entire modernisation was integrated into ongoing production operations, culminating in final commissioning by STAHL CraneSystems in October 2025.
The high-performance lifting upgrade included:
- Two double-rail trolleys: Each equipped with an ASF7063 main wire rope hoist capable of lifting heavy loads up to 35 tonnes.
- Adjustable lifting speeds: The main hoist features adjustable lifting speeds ranging from a precise 0.08m/min to a fast 4.20m/min.
- SHF4012 auxiliary hoists: Capable of handling up to five tonnes at speeds up to 8m/min to assist in versatile lifting tasks.
- Intelligent control technology: Package includes an SMC22 multicontroller, a central programmable logic controller (PLC) and an HBC master-slave radio system.
Intelligent tandem operation and safety controls
Safety and reliability are critical when moving massive steel bridge segments. The new master-slave tandem crane system operates across a 22-metre span with a 10-metre lifting height. To ensure stable data transmission and power delivery without the risk of wearing out sliding contacts, the hoists utilise an energy chain carrying protected Profinet and Profisafe cables.
Furthermore, the system features sophisticated, distance-controlled tandem operation with electronic load summation. The integrated PLC continuously monitors operating conditions to protect the building’s foundations. For instance, if the cranes operate within a four-metre trolley travel range, the total combined load is electronically restricted to 30 tonnes. To support full-capacity loads, the control system ensures the cranes maintain a distance of at least 11 metres. The safety systems conform strictly to Performance Level d (PL d), Category 2, executing an immediate safe shutdown if an overload occurs.
Streamlining the bridge workshop workflow
The integration of the new double-rail top-girder cranes has optimised the modular construction and assembly processes across the workshop’s four dedicated halls:
- Hall 1 (Machining): Initial fabrication operations, such as cutting, drilling and milling of bridge components take place here.
- Hall 2 (Welding Hall): Prepared steel components and heavy T-beams are assembled using the two new master-slave tandem cranes. Operators use an HBC-radiomatic ‘technos’ radio control transmitter, which allows on-site technicians to take temporary control via a slave unit for precision assembly.
- Hall 3 (Preservation): Welded structures are transported here for blast-cleaning with steel grit to remove scale before receiving a durable, anti-corrosion paint finish.
- Hall 4 (Storage and assembly): Completed bridge segments are paired with stored assembly components, prepared for transport and sent directly to construction sites.
High availability for demanding environments
The successful refurbishment proves that complex industrial crane upgrades can be planned and executed within a single year without stopping production. Thanks to the engineering expertise of STAHL CraneSystems and DKS, the DB Bahnbau Group is fully equipped with highly available, safe, and efficient infrastructure to support railway bridge construction for decades to come.
