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Omnidirectional concrete precast mover – 60 t


Omnidirectional concrete precast mover 60-t


Movement of pre-cast concrete structures in a manufacturing plant in South Dakota, USA for a well-established US company with a history of over 100 years in the US construction industry.


The company needed to move large pre-cast concrete panels of over 12 metres (40 feet) in length and weighing over 60 tons (130,000 lbs). These were to be transported on A-frame steel pallet structures and had to be operated both inside and outside the plant.


the solution proposed by Morello was to design and build 2 self-propelled OMNI-directional heavy duty platform carts to manage the movement of the concrete panels at the plant. The trolleys are 12 metres (40 feet) in length and are designed to lift A-frame steel pallets used to support and move the pre-cast structures. The steel pallets to support the long rectangular cement panels were designed and built by Morello so as to operate effectively with the trolleys.

To move the 60 ton (130,000 lbs) concrete panels the OMNI trolley is positioned beneath the steel pallet using the remote control device. The trolley is raised a few inches off the ground lifting the A-frame steel pallet on which the concrete panels are loaded, and can then be moved by remote control to its new location.


Steering: in order to manage and manoeuvre the long load within the plant’s limited spaces, OMNI or multi-directional steering was proposed so the trolleys could rotate in one place, move at 90°, or diagonally. This gives maximum steering flexibility. The OMNI trolleys also have an independent electric motor on each wheel.

Power autonomy: the heavy duty industrial carts must work continuously for many hours and for this reason are powered by lithium batteries which have 8km (5 miles) of effective use. The operating speed is 25 metres/min (82 ft./min.). In addition, the trolleys are driven by zero maintenance, high precision, brushless electric motors.

Suspension: as the trolleys must operate both inside and outside, they are equipped with a hydraulic suspension to manage uneven, imperfect surfaces.

Software: 100% Morello proprietary software developed over many years of experience with industrial applications.

Technical Support: the heavy materials handling equipment is equipped with advanced system diagnostics on the HMI. Remote assistance can also be provided directly from Morello HQ through the integrated IoT on-board devices. Morello also has an experienced US technical partner capable of providing hands-on technical support when required. The solution supplied to Morello’s US client company utilizes state of the art technologies designed to enhance factory operations. The experience gained over many years together with Morello’s project management processes ensure that no operating details are overlooked and full commercial and technical support is guaranteed at all times.