Ports and terminals handle a broad variety of breakbulk cargo, each with different shapes, surfaces, and handling requirements. The lifting solution needs to match both the load and the available handling equipment.
Aerolift supplies vacuum and mechanical lifting attachments for cranes, reach stackers, and forklifts, focusing on reduced manual intervention and integrating with existing operations.
This article covers the main handling challenges in ports, suitable lifting solutions, host machine integration, and practical examples from port and terminal operations. Prefer to watch? In the video below, Robert Lemm, CEO of Aerolift, shares his experience with breakbulk cargo handling and explains how Aerolift approaches these applications.
Port and terminal operations combine repeated lifting of heavy loads, large handling equipment, and people working in close proximity. Cargo is often lifted over longer distances and at height, while space around the load can be limited. When slings, hooks, spreader beams, clamps, or other lifting gear are used, personnel need to approach the cargo to attach or remove this equipment.
Reducing the need for people to work close to suspended loads can therefore lower exposure and create a safer working environment. With remotely controlled lifting attachments, the crane or machine operator can attach and release the load from the cabin, reducing the need for personnel to approach the load during the lifting cycle.
Within that safety margin, terminals also need to work efficiently. Breakbulk cargo is handled piece by piece, so handling speed, attachment and release time, and overall cycle time directly affect the operation.
At the same time, terminals need to handle different types and sizes of cargo. Flexibility is therefore important. A lifting attachment that can handle various pipe diameters or slabs measuring 3 to 9 meters in length, while compatible with existing host machines, can reduce the need for additional equipment and investment.
There is no single lifting method for all breakbulk cargo. Choosing the right lifting solution depends on surface conditions, shape, dimensions, weight, and the handling process required.
Vacuum lifting is particularly suitable for non-porous loads such as steel and aluminium plates, slabs, and bare or coated pipes with a smooth, non-porous surface. The vacuum creates a secure grip on the load surface, allowing quick attachment and release without hooks or clamps that can mark or damage the product and require manual handling. Access to the sides or ends is not required, which is useful when cargo is stored close together or against the vessel hold wall.
Mechanical lifting is better suited to loads that cannot be handled reliably by vacuum, such as porous surfaces, bundles or stacks. For pipe handling, a mechanical pipe spreader can also offer more flexibility when a wide range of pipe diameters needs to be handled.
Vacuum and mechanical lifting should therefore not be considered as competing technologies. Depending on the application, either method — or a combination of both — can provide the most practical solution.
Lifting attachments like vacuum lifters, mechanical grippers, and pipe spreaders can be designed for various host machines, including cranes, reach stackers, or forklifts. Their integration, whether with existing equipment or a new host machine, requires careful consideration of compatibility during engineering.
The lifting solution is adapted to the available host machine, considering the connection, power supply, controls, and lifting capacity. For cranes, the attachment is typically connected to the crane hook. On reach stackers, integration can be made through the standard container spreader.
Depending on the setup, the attachment can use electric or hydraulic power or operate with its own battery or generator.
With more than 60 years of experience in lifting and handling solutions, Aerolift has delivered projects across a wide range of industries, including ports and terminals. The examples below show how we have approached different cargo types and handling processes in port and terminal projects.
Nord Stream 2 involved several stages of pipe handling, each with different requirements. With around 220,000 pipes in the project, many of them were handled with Aerolift equipment at least five times across different stages of transport, coating, storage and vessel loading. This meant that one lifting principle was not automatically suitable throughout the complete process. Bare steel pipes could be handled with vacuum, while concrete-coated pipes required a mechanical solution. For vessel loading, pipe spreaders were used in combination with mobile harbour cranes. This allowed matching the lifting method to each process stage.
For aluminium slab handling at Steinweg in the Port of Rotterdam, the solution combined vacuum lifting with automatic mechanical locking arms. This allowed the handling concept to benefit from vacuum advantages while adding an extra layer of mechanical safety.
1. What types of breakbulk cargo does Aerolift typically design lifting solutions for?
Aerolift designs lifting solutions for breakbulk cargo such as bare and coated pipes, steel and aluminium plates, slabs, and paper rolls. The suitable lifting method depends on the load surface, dimensions, weight, and handling process.
2. Can one lifting attachment handle different types or sizes of cargo?
Yes. Where possible, Aerolift designs the lifting solution to cover a wider range of loads. For example, one main vacuum lifter can be equipped with different suction pad beams for handling pipes and plates. The required flexibility is considered at the start of the engineering process.
3. Can vacuum lifters be used outdoors, in rain, or in a marine/coastal environment?
Yes. Aerolift vacuum lifters are suitable for both indoor and outdoor use. The machines are coated according to ISO 12944 to protect them against corrosion. If needed, a specific category for corrosivity can be applied upon request.
4. What standards apply to below-the-hook lifting devices Aerolift supplies?
Aerolift machines are engineered and manufactured in accordance with internationally recognized standards, including:
• Machinery Directive 2006/42/EC and as from 2027: Regulation (EU) 2023/1230
• EN13155 — Cranes – Safety – Non-fixed load lifting attachments
• ISO 3834-2 — Certified welding quality standards
5. What support does Aerolift provide during commissioning and operation?
Aerolift supports customers throughout the lifetime of lifting equipment. This can include commissioning support and operator training to ensure the equipment is used correctly and efficiently. Spare and wear parts are available from the Netherlands, and where possible we select components from suppliers with worldwide coverage to support local availability. Service is provided worldwide through our field technicians and distributor network.
Handling pipes, plates, slabs, or paper rolls in a port or terminal? Discuss your load, handling process, and available host machine with our engineers to determine the most suitable lifting solution.
