PROJECT OF THE MONTH
“Historical Landmark of Civil Engineering in Germany” by the Federal Chamber of Engineers in 2022. The dam systems have now become a complex water management system. Monitoring, maintaining and servicing the structures is a major challenge. The operator of a total of 36 dams is Talsperrenbetrieb Sachsen-Anhalt (TSB), based in Blankenburg. It is responsible for striking a balance between water supply and flood protection every day. The entire Rappbode Dam system, which consists of
pre-dams and retention basins, contributes significantly to flood protection in the eastern Harz Mountains. In addition, an integrated power plant at the dam supplies electricity to surrounding villages. Without technical masterpieces, the optimal use of resources in harmony with nature would be inconceivable. Some of the technical equipment comes from STAHL CraneSystems, a company of the Columbus McKinnon Group.
Harmony with nature The cranes installed in the confined space of the dam wall are used to open the bulkheads at the foot of the dam. This so-called bottom outlet is located on the water side of the dam wall. Basically, this closable opening is used to empty the dam to the lowest water level intended for normal operation. The bottom outlet is usually regulated by a gate valve. After passing through the outlet, the water flows into a catch basin to reduce the flow velocity. Before the crane can open the bottom outlet, a submersible robot is lowered to the appropriate depth to hook the crane hook onto the eyelet of the bulkhead. As its name suggests, the bottom outlet is the deepest water extraction facility in a dam. This means that the lifting height of the crane and, due to the water load, its load capacity are crucial. There are two corresponding shafts in the Rappbode Dam, although only one has been modernised with a new crane from STAHL CraneSystems so far. Emptying the dam is not a particularly quick process, sometimes taking weeks or even months. For this reason, the crane is only used occasionally throughout the year to open the bulkhead – but when it is used, it must be ensured that the crane is in full working order. The old crane, which was installed in 1960, was adequately dimensioned with a rope length of 96m and a load capacity of 16t, but due to decades of operation, it was increasingly in need of maintenance. For this reason, a comprehensive modernisation was planned for 2024. The rope manufacturer, Voigt Seil- und Hebetechnik in Bad Düben, specialises in wire and fibre ropes as well as all solutions relating to rope and slinging technology. Due to the many possible applications of rope and lifting technology products, almost all sectors of the economy are among its customers, including TSB. Voigt is particularly committed to environmental protection and sustainability. The rope manufacturer has already provided service support to TSB in the past. For this reason, the modernisation project was also entrusted to this specialist in rope and lifting technology. A key factor in the project was to ensure the previous load capacity of 16t with an increased lifting height of 100m, as the original 96m was no longer sufficient. The crane, which dated back to the 1960s, had particular
disadvantages in terms of the crane and trolley drives, which were still equipped with outdated and disruptive reel chains (chain drive). The new installation of the crane system also included the replacement of these manual drives with modern electric travel drives. The new solution impresses with its higher efficiency, reliability and travel speeds, as well as minimal maintenance, improved comfort and maximum user safety. Due to structural challenges, the Voigt rope factory had
to find a solution that would fit through a narrow hatch and into small spaces. The possible distance between the crane runway and the lower edge of the ceiling was very small, which is why a custom-made solution was necessary, which could best be designed with the CraneKit from STAHL CraneSystems. This allows such projects to be planned economically and executed quickly with manageable effort. Another advantage is its flexibility, which allows the respective solution to be adapted to specific requirements. STAHL CraneSystems produces all components of its CraneKits at its factory in Künzelsau in Germany.
www.hoistmagazine.com | March 2026 | 9
With an opening of only 2m x 4m, the hatch and the installation space are extremely narrow.
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