PROJECT EXAMPLES
DIMENSION CARGO
1 Transformer: 11,10 m x 3,68 m x 4,41 m, 280 t (LxBxH)
OVERALL TRANSPORT DIMENSION
Max. 87,5 m x 4,65 m x 5,60 m, 610 t (LxBxH)
VEHICLE TECHNOLOGY USES
- Max. 2x 20 THP axles combined with side girder bridge G² | K600, a total of 4x reconfiguration of the vehicle combination and use of three different vehicle variants
- Bridge overpass system

DEFYING DESPITE MISSING/DECAYING INFRASTRUCTURE
Due to irreparable damage to a transformer at the Dahlem substation, we were commissioned at short notice to transport the replacement transformer. As the infrastructure in the Dahlem area has been severely damaged by the flood disaster and some transport routes are no longer usable, our work to ensure supply security began already in nearby Kall. There, we took over the transport at a temporarily established rail-to-road transfer point and began the five-day journey from Kall to Dahlem (covering 30.6 transport kilometers).
Special Challenges:
- Missing/decaying infrastructure
- Reinforcement of a rail-to-road transfer point
- Use of our bridge overpass system behind/in front of a 90-degree curve
- Route with inclines of up to 8%
- Very narrow clearance profiles
- Three different vehicle combinations
- 4x modification of the vehicle combination
- Max. transport dimensions: 2x 20 THP axles, L 87.5 m x W 4.65 m x H 5.60 m, 610 t total weight
Four months prior to the start of the transport, we were commissioned to develop a transport route due to irreparable damage to a transformer. To this end, a suitable route from a transfer point to the Dahlem substation had to be identified, planned, and prepared.
Transformers of this size are usually delivered by rail. Due to the flood disaster in the Ahr Valley, these rail connections were not available. The nearest rail connection in combination with access to a suitable heavy-duty route was located in Kall, but far from a conventional transfer point. Up to 60 tons of gravel were used to improve the access roads, enabling us to reach and later depart the specially constructed transfer point using our G² | K600 side girder bridge and 12 THP axles on each side.
In the tightest of spaces, mobilization and setup of the equipment on site began two days prior to the transport date. At certain times, up to three trades were working simultaneously in the rail area, making precise planning and coordination essential.
After loading was completed, the first challenge arose off public roads. Due to the development work on the access roads, a gradient of 5% had to be overcome.
Therefore, we had to move our transport, with a total length of 75.5 m, a total width of 4.65 m, a total height of 5.60 m, and a total weight of 548 tons, from the outset with two additional prime movers, totaling 2,600 HP – no problem for our well-rehearsed team.
Due to the insufficient load-bearing capacity of a bridge over the Urft, it had to be bridged using our bridge overpass system (BÜFS), with a length of 25 m plus 12 m of ramps, and crossed. The bridge was located directly after a 90-degree curve and ended in another curve. This required millimeter precision to protect the already damaged infrastructure of the Ahr Valley as much as possible. Thanks to the design of our G² | K600 side girder bridge, we can configure the vehicle combination with 2x 12 axles and a bolster length of 34 m in a very compact setup and, despite the transformer weight of 280 tons, maintain axle loads below 20 tons. Within two hours, we were able to cross the BÜFS and thus master the first special challenge of the transport.
Further along the transport route, an 8% incline had to be negotiated. This meant our two additional prime movers were once again deployed, and we moved through the Eifel at night with a total weight of 618 tons and 2,600 HP. After passing through three roundabouts, we reached the first stage destination and preparations for the second leg could begin.
Due to several bridges along the further course of the transport route, we had to reduce our axle loads, and an additional 16 THP axles were mounted on the B258, which was closed for us. This resulted in dimensions of L 87.5 m x W 4.65 m x H 5.60 m with a total weight of 610 tons. At the beginning of the second leg of the transport, a roundabout had to be passed, which we managed by means of a load transfer maneuver. Another load transfer maneuver then brought us to a planned stopover.
To pass under a pedestrian bridge, it was necessary to dismantle and immediately reassemble the inner 8 THP axles so that the transformer could be lowered as much as possible. The assembly work was carried out within a single-lane closure with traffic light control. After two further turns, the second stage of the project was also completed.
A final conversion phase, back to 2x 16 axles, dimensions L 87.5 m x W 4.65 m x H 5.60 m with a total weight of 570 tons, was essential for the last leg due to local conditions, as we had to pass under two more bridges.
Another 90-degree curve, flanked by buildings and masonry on both the inner and outer radius, pushed both people and equipment to their limits in the project’s final challenge.
After maneuvering the front 16 axles through the curve, millimeter precision was required for the rear 16 axles. Thanks to the high flexibility of our G² | K600 side girder bridge, we were able to overcome this obstacle as well.
For the final kilometer of the transport route, an additional prime mover was deployed due to a five percent incline along the way.
We reached our destination, the substation in Dahlem, safely and on schedule.
Due to local conditions, the state of the local infrastructure and construction, as well as the topography, this project was a challenge for both man and machine. Through the use of our unique G² | K600, we were once again able to demonstrate the resilience and flexibility of the design and provide our customer with a unique solution.
DIMENSION CARGO
1 Generator: 13,160 x 4,130 x 4,320 mm (L x W x H), 365 t
1 Transformer: 12,590 x 4,000 x 4,590 mm (L x W x H), 382 t
1 Flywheel: 8,070 x 3,350 x 2,900 mm (L x W x H), 182 t
OVERALL TRANSPORT DIMENSION
Generator: max. transport dimensions 31.25 m x 6.09 m x 6.00 m (L x W x H), 517 t
Transformer max. transport dimensions 31.25 m x 4.90 m x 5.80 m (L x W x H), 540 t
Transformer max. transport dimensions 50.00 m x 3.55 m x 4.25 m (L x W x H), 322 t
VEHICLE TECHNOLOGY USES
- 18-axle SPMT (self-propelled modular transporter), 1.5-times coupled, 12-axle SPMT, parallel coupled, 18-axle THP (modular trailer), parallel coupled. Side girder bridge G² | K600, mounted on 2 x 16-axle THP modules
- Deployment of Bridge Fly-Over Systems:
1 fly-over system, 15 meters, 3 lanes
1 fly-over system, 20 meters, 3 lanes

SOPHISTICATED MULTIMODAL MEGA PROJECT
For the Würgassen substation, three heavy components – a 365-ton generator, a 182-ton flywheel, and a 382-ton power transformer – had to be transported from the manufacturers’ facilities to the southern Weser Uplands. Despite extremely short preparation times, we successfully asserted our transport concept against the competition and ensured the availability of all necessary equipment at all times. This allowed us to adhere to the specified project schedule, even in the face of highly fluctuating water levels on the Weser River.
Special Challenges:
- Transport duration: 6 weeks
- Strongly fluctuating water levels
- Roll-off pontoon positioned across the main river flow (cross currents)
- Use of a push boat
- Very limited time window for planning and execution
- Constraints due to curve radii and clearance profiles
- Crossing of a railway line with a time window of approx. 2–3 hours
- Driving simulations and tachymetric measurements
- High safety requirements
- A total of 5 different vehicle configurations
- Simultaneous deployment of two bridge fly-over systems
In addition to the task of transporting three major components from the manufacturing sites to the Würgassen substation, all necessary preparations had to be made within an extremely short time frame.
Due to the local conditions, driving simulations, tachymetric measurements, and several coordination meetings – particularly in consideration of ground load-bearing capacities – were required to ensure a fast and safe execution of the transports.
Challenges arose due to limitations imposed by curve radii and clearance profiles, which required precision down to the millimeter given the overall transport dimensions. Additionally, there was constant time pressure caused by fluctuating water levels and currents of the Weser River, resulting in very narrow time windows for the roll-off operations from the pontoon.
Further complicating the process was the fact that the pontoon had to be positioned crosswise to the main current (crossflow) of the Weser to align with the ferry ramp for the roll-off procedure. The entire operation was secured by an additional push boat.
Despite the continuous pressure to maintain the schedule, all prescribed safety regulations were strictly observed and adhered to at all times.
Following the successful roll-offs of each component, two separate night transports were required for both the generator and the power transformer. The flywheel was transported from the Eulenkrug ferry ramp in Derental to the Würgassen substation in a single night.
In addition to the sheer size of the components, the extensive special equipment, the local conditions, and the resulting logistical complexity, this project presented a unique challenge. Due to the limited load-bearing capacity of two bridges along the transport route, our bridge fly-over system had to be installed on both bridges simultaneously. This required a clear structure, close coordination, and a flawless logistics chain, as even the slightest delay could have disrupted the entire schedule.
Crossing a railway line added another layer of complexity, demanding a strictly timed and meticulously planned schedule, since the crossing could only be executed within a time window of approximately 2–3 hours.
The delivery of the components was initially carried out using an 18-axle, 1.5-times coupled self-propelled modular transporter. For final positioning at the substation, a conversion to a 12-axle, parallel-coupled self-propelled transporter was necessary due to the highly confined space on-site.
In addition to the tight spatial constraints, both the delivery and the vehicle conversion had to be carried out during ongoing construction operations and under strict adherence to the site’s safety regulations – all of which we fulfilled to the highest satisfaction of our client.
Within a period of six weeks, we successfully transported approximately 1,700 tons using a workforce of up to 25 employees. The operation involved 51 axle lines of SPMTs in two configurations (18A 3-file and 12A 4-file), five prime movers, and six semi-trailers for the mobilization and demobilization of our fly-over system for each heavy transport. The project also required multiple crane operations coordinated by our team, 28 axle lines combined with our side girder bridge G² | K600 (pre-staged from Mönchengladbach-Krefeld), as well as several tons of additional equipment. Throughout the entire project, we met all requirements and specifications – consistently to the full satisfaction of our client.
DIMENSION CARGO
Generator: 9,76 m l x 4,15 m w x 4,32 m h , 350 to
OVERALL TRANSPORT DIMENSION
105 m l x 6,30 m w x 5,70 m h , 798 to
VEHICLE TECHNOLOGY USES
- Use high girder bridge G² I K600
- Various transport options, use hydraulic lifting gantries und fly over bridge
- Permanent transport change from 2 x 26-axle high girder bridge G² I K600 to 2 x 16-axle high girder bridge G² I K600
- Permanent double staffing required due to the transport process
MULTIMODAL HEAVY TRANSPORT WITH A TOTAL WEIGHT OF 798 TONNES
A 350 tonnes generator from the Ibbenbüren power plant, which has already been shut down, is to be transported to the active Niederaussem power plant as a reserve generator. At the same time, the defective generator at the Niederaussem power station is to be moved to a different position.
Our task initially consisted of preparing the feasibility study and transporting both generators to Niederaussem and then positioning them within the power station.
After detailed CAD simulations, route tests, static calculations, method statements, risk assessments, etc. as well as multiple coordination meetings on site with representatives of the authorities and stakeholders, which took around 6 months, the transport could be realised.
The lack of generator end plates for this type of generator and the resulting overall dimensions of the transport variants made the project a particular challenge for man and machine.
MoreDIMENSION CARGO
7 girder (pretressed concrete bridge)
per girder, 45,69 m l x 1,58 m w x 1,44 m h , 110 to
OVERALL TRANSPORT DIMENSIOM
61 m l x 3,00 m w x 4,25 m h , 199 to
VEHICLE TECHNOLOGY USES
- 6-axle Trailer with 8-axle self-propelled trailers
- 6-axle SPMT (Self-propelled modular transporter)
GERMANY’S LONGEST PRESTRESSED CONCRETE BRIDGE
Delivered safely and on time. Germany’s longest prefabricated prestressed concrete bridge. The special feature of the new record-breaking structure, the length of 45 metres. This innovative construction method means that the central pier can be dispensed with, which halves the overall construction time.
For this unique structure over the A1 near Ascheberg, we supplied a total of seven girders, each 45 metres long and weighing 110 tonnes each.
We are pleased to have been able to make our contribution to this record-breaking structure and to be working together on the modernisation of the German infrastructure.
DIMENSION CARGO
1 Transformer 1100 kV (World’s most powerful fransformer)
13,35 m l x 6,14 m w x 5,87 m h , 535 tons
OVERALL TRANSPORT DIMENSION
64,30 m l x 7,45 m w x 6,45 m h , 875 tons
VEHICLE TECHNOLOGY USES
- High Girder Bridge G² I K600
- Front: 2 power packs with 2 x 10 axle lines SPMT (Self-propelled modular transporter) parralel coupled
- Back: 2 x 10 axle lines SPMT (Self-propelled modular transporter) parralel coupled
RECORD TRANSPORT – TRANSPORT OF THE WORLD’S MOST POWERFUL TRANSFORMER
Already 12 months before the largest transformer ever built by Siemens – destined for China – started the first inner-city eight kilometres from the manufacturing plant to the port in Nuremberg, the specialists of the KAHL group of companies became active. The feasibility study commissioned by the customer required various route reconnaissance, elaborate measurements, carefully prepared official procedures and the assurance that suitable transport technology was available. For the enormous transformer with a transmission voltage of 1100 kV, and thus the world’s most powerful converter transformer, weighed in at 535 tonnes with a length of 13.35 m, a width of 6.14m and a height of 5.87m.
Based on load image and CAD simulations (EasyTrack, EasyLoad), the appropriate vehicle configuration was worked out in coordination with the engineering offices involved, which were commissioned with the static recalculations of the total of four bridge structures to be crossed.
Thanks to the innovative equipment of the KAHL group of companies, a vehicle combination could be provided which fulfilled all requirements for this record-breaking transport.
DIMENSION CARGO
1 home: 12 m l x 8,45 m w x 6,50 m h , 200 tons
OVERALL TRANSPORT DIMENSION
55 m l x 8,45 m w x 7,50 m h , 365 tons
VEHICLE TECHNOLOGY USES
- 22-axle heavy-duty modules
- 10-axle SPMT (Self-propelled modular transporter)
SIMPLY MOVE WHOLE HOUSES.
The challenge of the customer’s request was to lift a historic 65-year-old settlement house weighing 200 t (dimensions 12 m long, 8.45 m wide and 6.0 m high) from the basement foundation without distortion and in one piece and to move it from its location to the main road in the middle of a housing estate with different street levels, then to transport it over public roads and to place it on the newly constructed foundation at the destination without major interventions in the surroundings. Everything had to be done under the aspect of relocation, with the positioning at the new destination as true to the original as possible. The statics of the transport goods were particularly problematic because of its low stability due to a double wall with air chambers.
MoreDIMENSION CARGO
1 Turbine: 14,22 m l x 3,73 m w x 3,57 m h , 115 tons
OVERALL TRANSPORT DIMENSION
- 1x 4-axle truck
- 13-axle trailer
ANTONOV LOADING
Road, rail or waterways are usually available for the realisation of large-volume and heavy transports. But when things have to move particularly fast, there is fortunately another option – air freight. Since the 114-tonne turbine and its accessories were needed for an urgent overhaul and had to be delivered within a very narrow time window, there was only one solution – the Antonov An 124-100.
We took over the first section from the manufacturer to Cologne/Bonn Airport with our 13-axle modular chassis, which was pulled by a four-axle tractor. Arriving safely at the airport on schedule, one of the world’s largest aircraft for heavy loads – an Antonov An 124-100 of Volga-Dnepr Airlines – was waiting in the cargo area of the airport. The four-engine shoulder-wing aircraft with an impressive wingspan of over 73 metres was already waiting for its cargo with the nose flap up and the stowage system in place. With a crew of six, it can carry a maximum load of 120 tonnes, bringing its take-off weight to 392 tonnes. The turbine was loaded from our vehicle onto the Antonov’s loading ramp by a mobile crane with a maximum load of 500 tonnes. Pulled by steel cables, the turbine disappeared quite quickly into the large hollow belly of the machine. The load was securely fixed in a precisely defined position to prevent any movement during the flight. With so much weight in the belly, the fuel of the An 124-100 was initially sufficient to reach Athens. From there, after refuelling, it continued to its destination, the airport in Jeddah on the west coast of Saudi Arabia. With its cargo removed, the aircraft returned to Cologne/Bonn to pick up the turbine’s accessories.
DIMENSION CARGO
4 tranformers, each12 m l x 3,98 m w x 4,48 m h , 326 / 307 tons
OVERALL TRANSPORT DIMENSION
112,50 m l x 6,28 m w x 5,55/4,60 h, 742/ 766 tons
VEHICLE TECHNOLOGY USES
- 2x 24 axle lines high girder bridge G² I K600
- 1x 22 axle lines PST/SLE (SPMT/Self-propelled modular transporter)
- Fly-over bridge system
MULTIMODAL TRANSFORMER TRANSPORT
For the extension of the Würgau transformer station, 4 transformers with 326 + 307 t were transported multimodally from the transformer station in A-Weiz via the Danube port of Linz to the transformer station via the port of Bamberg. The pre-carriage was carried out by 32-axle Schnabel wagon (rail) to the heavy goods terminal in Linz, and then by inland waterway vessel to the port of Bamberg. For the unloading from the inland vessel and the subsequent loading into the 2 x 24-axle side girder bridge G² I K 600, we used a 900 t crawler crane. The task was not only to be able to carry the axle load of 12 t for the motorway bridges, but also the required clearance height for the good 4.5 metre high transformers! With a total train length of 112 metres, a width of 6.30 metres and a total train weight of 757 tonnes, it was possible to realise the required axle load of 12 tonnes on the structures by using another 10-axle running gear under the load. For the last part of the route to the transformer station, a reloading onto a 22-axle SPMT was necessary in order to cope with the 9% gradients with the serpentines.
MoreDIMENSION CARGO
1 gas turbine: 12 m l x 3,98 m w x 4,48 m h , 338 tons
1 generator: 12 m l x 3,98 m w x 4,48 m h , 308 tons
1 transformer: 12 m l x 3,98 m w x 4,48 m h , 275 tons
VEHICLE TECHNOLOGY USES
- 22-axle heavy-duty modules(3-file)
- 6 trucks
- 14-axle SPMT (Self-propelled modular transporter)
FUTURE POWER SUPPLY SECURED
For the new construction of the gas-fired power plant Irsching 6, 3 plant components (gas turbine 338 tons, generator 308 tons and transformer 275 tons) had to be transported from the port of Kelheim to Voburg on the Danube.
The project included crane handling at the port, transport to the power plant, transhipment with mast and interim storage with SPMT, as well as subsequent internal transport with SPMT and foundation setting with mobile strand lifting system.
An entire logistics chain with crane, transport and assembly was required here. In addition to the special requirements due to the Corona pandemic (constant checks of all employees and special protection), the power plant operator also placed very high demands on occupational health and safety and environmental protection due to the immediate proximity to the Danube.
MoreDIMENSION CARGO
1 generator: 3,60 m l x 3,25 m w x 3,00 m h , 40 tons
TECHNOLOGY USES
- Push and pull skidding system
- 16 m long steel girders
- Load distribution plates
- 2 heavy-duty towers made of 8 elephant feet
- Heavy duty platform
- Working scaffold
- Mobile crane
DISASSEMBLY AND INSTALLATION OF A 40 to GENERATOR AT VW BAUNATAL
At the VW Baunatal power plant, a 40-tonne generator had failed and needed a general overhaul. We were commissioned with the removal (and later the installation) of the generator.
The special challenges of this installation work lay on the one hand in the insufficient load-bearing capacity of the floor area in front of the Geno, which only allowed 15 kN/m², and on the other hand in the actual removal from the building shell at a height of 9.20 m, only possible by dismantling the outer wall, up to the point of loading.
Due to complicated, time-consuming negotiations with external structural engineers and the customer about the unworkable concept presented by the customer’s structural engineering office, we ran out of time. In the end, our proposed solution prevailed.
With our own shifting track, the hydraulic lifting of the Geno, the substructure of 16m girders, various load distributors and the assembly of a steel construction, we moved the generator from its place to the outside and loaded it with a truck-mounted crane.
DIMENSION CARGO
1 phase shifter: 13.44 m l x 4.13 m w x 4.33 m h , 357 to
OVERALL TRANSPORT DIMENSION
60 m l x 6.40 m w x 6.40 m h, 684 tons
VEHICLE TECHNOLOGY USES
- High girder bridge G² I K600
- 2 x 18 axle lines PST/SLE (SPMT/Self-propelled modular transporter)
GENERATOR- TRANSPORT FOR SECURITY OF SUPPLY
The transport of a rotating phase shifter with a transport weight of 357 t from the Siemens Energy generator plant in Mülheim to Ludwigsburg-Hoheneck to the transformer station of the electricity grid operator Amprion, could only be carried out in a combined logistics chain with inland vessel, 650 t crawler crane for handling and the unique G² I K 600 boiler bridge, combined with 2×18-axle PSTE self-propelled units (SPMT) for the on-carriage.
After completion of the on-carriage, reloading onto a separate 18-axle self-propelled unit was required to bring it into the nacelle. We carried out the unloading with two masts in tandem lift. Extensive preparations, studies and calculations had to be taken into account in advance for the on-carriage from the port to the foundation.
MoreDIMENSION CARGO
1 Stator: 14,68 m l x 4,20 m w x 4,50 m h , 400 to
VEHICLE TECHNOLOGY USES
- High girder bridge G² I K600
- 2x 26-axle heavy-duty modules
- 2x 14-axle heavy-duty modules
- 2x 14-axle SPMT (Self-propelled modular transporter)
- 2x 10-axle SPMT (Self-propelled modular transporter)
BRAVURA PERFORMANCE IN FIVE VARIANTS
The generators of RWE’s Voerde power plant, which is currently being dismantled, are to be used as a strategic reserve for other locations. We had the task of taking over, removing and transporting the generators, each weighing 400 t, at a height of 13.4 m above the foundation and setting one of the generators down at the Neurath power plant.
This was preceded by almost a year of detailed preparation, including the preparation of CAD assembly and transport simulations, route tests, static calculations, method statements, risk assessments and coordination meetings with representatives of the authorities.
Challenges were the tight space conditions for the deployment in the nacelle, at the Nato ramp for RoRo loading and the restrictions with regard to axle loads and clearance profiles with vehicle dimensions of up to 105 m length x 4.68 m width and 5.70 m height and a total weight of 798 tonnes.
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