Development of Giant Crane Technology
Sarens initiated the in-house development of its Sarens Giant Crane (SGC) series in the 2010s, leveraging ring-lift technology to handle ultra-heavy loads beyond the capabilities of conventional mobile cranes.[45] This approach positions the crane's upper structure on a circular ring track, enabling 360-degree slewing and enhanced stability for lifts exceeding thousands of tons, as demonstrated in the inaugural SGC-120 model introduced in 2018.[46] The design process emphasized modularity, allowing components to be scaled and configured for diverse project demands while maintaining structural integrity under extreme conditions.[45]
To ensure safety and interoperability, the SGC series adheres to European standards EN 13000 for mobile cranes and EN 13001 for general crane design, with components tested at 125% of rated loads for both dynamic and static scenarios.[47] This compliance facilitates modular assembly and disassembly, incorporating fail-safe systems like safety PLCs and high-quality components to mitigate risks in high-stakes operations.[47] By aligning with these norms, Sarens' engineers integrated advanced control systems that monitor load distribution and prevent overloads, enhancing overall reliability without compromising lifting performance.[46]
A pivotal evolution in the SGC lineup occurred in the 2020s with the adoption of electric and hybrid powertrains, aimed at minimizing emissions and operational noise, beginning with the SGC-90 launched in 2020.[48] This fully electric model connects to the national grid, regenerating excess energy during load lowering to achieve up to 40% reduction in consumption, eliminating exhaust emissions and hydraulic oil risks.[49] Subsequent models, such as the SGC-170 introduced in 2025, extended this hybrid capability, combining battery storage with grid power for sustainable heavy lifting in environmentally sensitive sites.[50]
The SGC designs incorporate containerizable modularity, enabling transport via standard 40-foot containers—up to 160 for larger units like the SGC-120—to streamline global deployment and cut on-site assembly from months to weeks.[51] This feature reduces logistical complexities, as components arrive pre-assembled where possible, allowing crews to focus on ring installation and final integration rather than extensive fabrication.[45]
Sarens has committed substantial R&D investments to the SGC program, including in-house engineering for load moment calculations and stability simulations to optimize performance under variable conditions.[52] These efforts involve proprietary software for dynamic modeling, ensuring precise predictions of crane behavior during lifts, and occasional collaborations with specialized firms for validation of complex simulations.[20] Such advancements have positioned the SGC series as a benchmark for ultra-heavy lifting innovation, with ongoing investments supporting fleet expansions like the design and production of the fifth unit.[22]
Notable Giant Cranes
Sarens' Super Giant Crane (SGC) series represents the pinnacle of heavy-lifting technology, with several models achieving record capacities and enabling unprecedented infrastructure feats. The flagship SGC-250, known as "Big Carl," boasts a 250,000 tonne-metre load moment and a maximum lifting capacity of 5,000 tonnes, making it the world's largest land-based crane.[53][54] Launched in 2018, it features a modular ring design with a 118-160 metre main boom, a 100-metre jib, and a maximum height of 250 metres, allowing lifts at radii up to 275 metres.[53][55] Its debut project was the Hinkley Point C nuclear power station in the UK, where it has performed numerous lifts, including installing a 245-tonne reactor dome in 2025 and a polar crane within the reactor building.[56][57]
Following closely, the SGC-170, unveiled in July 2025, offers a 170,000 tonne-metre load moment and 3,200-tonne lifting capacity, positioning it as the second-most powerful in the fleet.[58][50] As an all-electric model, it emphasizes sustainability with grid connectivity and regenerative braking to recover energy during load lowering, reducing emissions on sensitive sites.[59] Named "Big Matthias" after R&D Manager Matthias Sarens during its christening in September 2025, it builds on the series' modular transport system, where components are shipped via self-propelled modular transporters (SPMTs) and assembled on-site for efficient deployment.[18][46]
The SGC-120 and SGC-140 models, introduced in the 2010s, provide versatile capacities of 120,000 to 140,000 tonne-metres, supporting a range of megaprojects.[60][61] The SGC-120, nicknamed "Big Benny," has been instrumental in nuclear installations, such as lifting reactor vessels at the HPCL refinery in India and executing engineered lifts at the Browns Ferry Nuclear Plant in the US.[62][63] Meanwhile, the SGC-140 has facilitated bridge installations and petrochemical upgrades, including brownfield replacements and greenfield constructions, thanks to its adaptable boom and jib configurations.[64][61] Both models incorporate transport modularity, with disassembled parts moved by SPMTs to minimize road impact and enable rapid setup.[65]
Rounding out the electric innovations, the SGC-90, dubbed "Little Celeste," delivers a 90,000 tonne-metre capacity as Sarens' first fully electric ring crane, launched in 2020.[48][66] Named after the granddaughter of founder Frantz Sarens, it connects directly to the power grid for zero-emission operation and regenerates electricity during descent, feeding surplus back to the site.[48][67] Designed for the energy transition, it has supported offshore wind projects like Taiwan's Greater Changhua windfarm, lifting turbine components while minimizing environmental impact.[68][69] Its modular design allows transport in sections, facilitating use in urban or ecologically sensitive areas.[70]
These SGC models have collectively enabled record-breaking lifts, such as reactor dome placements at Hinkley Point C and heavy vessel installations in refineries, showcasing Sarens' expertise in modular transport and assembly for global megaprojects.[57][62]