11 mins
A RESIDENTIAL HIGH-RISE BOOM
High-rise residential construction is seeing a surge, Mitchell Keller reports. What new products, projects, and processes are shaping the segment?
A view of the Couture tower in Milwaukee, US, overlooking Lake Michigan
With each passing year, more and more humans will be living in the sky. Skyscrapers, that is, as highrise residential construction is expected to boom in the coming years. Just a quick glance around the globe reveals that major projects are unfolding in every corner: from the US to the UK to Australia, Brazil and Scandinavia – almost every major metro is planning a newer, bigger, more unique project.
But rising materials prices and a strained
labour market are impacting the segment, and
creative solutions are needed both on-site and
in manufacturing the machines and products
that build the world’s high-rises. How is the
industry reacting and with what new solutions?
Spotlight on China
Let’s start first in the country that builds more high-rises than any other (every year): China.
China’s leading crane manufacturers continue to push the boundaries of tower crane innovation in both size and tech, introducing new models with increased lifting capacities, improved safety features, and advancements in automation and digitalisation.
International Construction (ICON) caught up with three of the country’s biggest crane OEMs: XCMG, Sany and Zoomlion. XCMG says it has made significant breakthroughs in large-scale tower crane technology, particularly in the 10,000 tonmeter class.
Its new models, including the XGT15000600S and XGT23000-760S, have been deployed on major infrastructure projects, such as the Changtai Yangtze River Bridge and the Ma’anshan Railway and Highway Bridge.
The XCMG XGT1350-64S tower crane
“During the development of the XGT15000-600S ultra-large tower crane, XCMG successfully overcame more than 60 key core technologies, achieved ten world-first innovations in the tower crane industry, and set ten world records in the industry,” the company tells ICON. The XGT23000-760S, the largest tower crane developed by XCMG, will be used on the Guangzhou Nansha Wanlong Bridge, a key self-anchored suspension bridge project.
A fleet of XCMG tower cranes working a major construction site in China
IMAGES: XCMG
Peri Formwork Systems’ solutions on the Couture high-rise project in Milwaukee, US
IMAGE: PERI FORMWORK SYSTEMS
XCMG says that it is also advancing digitalisation, with AI-driven obstacle avoidance and predictive maintenance features, as well as remote operation systems designed to improve safety and efficiency. Another China-based OEM, Sany has launched its flagship SFT3360 (T85320180) tower crane, designed for large-scale infrastructure projects such as thermal power plants and bridges. Dubbed the ‘King of Thermal Power Construction,’ the crane offers a 3,360 tonne-meter rated lifting rating and a maximum lifting height of 350m.
“Conventional cranes face 30% higher brake failure risks above 200m. The SFT3360 reduces this risk to less than 0.5%, thanks to its intelligent safety features,” says Sany chief engineer Qin Zhisheng. The crane features a ‘SkyEye’ monitoring system for real-time risk alerts, as well as hydraulicassisted assembly that accelerates installation by 20%. It is also designed for energy efficiency, consuming 15% less power per lift, aligning with sustainability goals in large-scale infrastructure projects.
Sany’s SFT3360 tower crane
IMAGE: SANY
Zoomlion’s ‘world’s first’ 20,000-ton-metre tower crane on the Bridge of Chaohu-Ma’anshan Intercity Railway project
IMAGE: ZOOMLION
Zoomlion says it is focusing on high-end, intelligent, and green tower crane development.A company spokesperson tells ICON they developed the world’s largest tonnage tower crane last year: the R23800-730.
Zoomlion states, “Through continuous exploration, we have broken through more than ten core technologies for super-large tower cranes, including the design and manufacturing of large-scale cross-section heavy-duty split structures and high-lift, high-torque lifting systems.”
Q&A WITH MICHAEL KENNEDY, CEO OF DOKA USA
Doka USA CEO Michael Kennedy joinedInternational Constructionfor an exclusive interview on segment trends, sustainability initiatives and the future of the industry
What trends are shaping the formwork and shoring industry?
One of the biggest challenges in construction right now is the labour shortage. Doka’s products are designed to be easier to use while still being extremely robust. By making formwork lighter, stronger, and easier to assemble, construction teams can work more efficiently.
This also improves safety on-site, as simpler systems reduce the need for excessive manual labour and complex installations. More than ever, contractors are looking for solutions that streamline processes and reduce reliance on highly skilled labour, and innovation in formwork design is responding to that demand.
How is Doka responding to sustainability demands in construction?
Doka is launching Xlife Top, a new recycled material product debuting at Bauma. This solution combines the best elements of wood and plastic while integrating a recycling component that extends the longevity of formwork.
After its use, instead of being discarded, Doka collects and grinds it down for reuse, significantly reducing waste. In addition, the company is developing recycled plastic sheathing for form panels, which increases durability and reduces the frequency of replacements. As sustainability becomes a growing priority in the industry, finding ways to minimise material waste and improve product lifecycle management is a key focus.
How is technology improving efficiency in formwork?
Doka has developed products that monitor concrete temperature and pressure in real time, helping contractors make informed decisions on-site.
By tracking these factors, teams can determine the optimal time to remove formwork, reducing downtime while ensuring structural integrity. This also minimises the risk of formwork failures, improving overall safety. The integration of digital monitoring tools is becoming more prevalent in construction, allowing teams to work with greater accuracy and efficiency.
The Liebherr 620 HC-L18/36 tower crane
IMAGE: LIEBHERR
LIEBHERR LAUNCHES NEW LARGE LUFFING JIB TOWER CRANE
Liebherr has introduced the 620 HC-L18/36, a new 600-tonne-metre class luffing jib tower crane, designed for high-rise and urban construction sites where space is restricted. Positioned just below the 710 HC-L32/64, it becomes the second largest in Liebherr’s luffing jib model range and expands the company’s offering to nine models, starting from 12-tonne capacity. The 620 HC-L18/36 offers a maximum lifting capacity of 18 tonnes on a single fall of rope, or 36 tonnes on two falls. With a 65m maximum jib length, it can lift 7.65 tonnes at its longest radius. The 620 HC-L’s out-of-service radius is just 12m, and its minimum operating radius is 4.1m.
Liebherr highlights the crane’s compact footprint and fast erection, key priorities for urban construction.
Markus Kinateder, Liebherr’s product manager, lifting solutions, tells ICON, “Out of service radius is a big issue on high-rise sites. The tighter we can make it the more cranes can be placed on-site and the closer they can get to the building for better load coverage.”
The crane’s erection process has been streamlined with plug-and-play electrical connections and pre-reeved hoist ropes, helping reduce on-site setup time. “We’ve completely rethought how we deliver these cranes to site. The goal is fewer trucks, fewer components to handle, and a more straightforward assembly process,” adds Benedikt Bärtle, head of tower crane centre and solutions for Liebherr.
The company is integrating digital intelligence into its products, with remote-controlled tower cranes, AI-driven safety features, and anticollision systems.
“Zoomlion tower cranes are equipped with intelligent control and anti-collision systems, enabling full-process intelligent safety control,” the company says. Its smart manufacturing facility, the largest of its kind, produces tower crane components with precision automation, enabling the company to assemble a new crane every 18 minutes, it says.
New tech below the hook
One emerging technology, the Vita Load Navigator (VLN) from US-based Vita Industrial, is changing how contractors manage crane lifts in complex urban environments. The VLN is load control system that uses AI, sensor, and remote-control technology to stabilise and position heavy loads during lifting operations. Particularly for heavy lifts involving products with large surface areas (like precast concrete pieces), the VLN can increase precision control and reduce material spinning. Caleb Rosenberger, global account manager with Vita, notes the product also assists in urban environments where one of the biggest challenges in city construction is manoeuvring materials around obstacles, such as power lines and existing structures. “On a recent project in Denver, a contractor was constructing a 200unit apartment complex near power lines. They had to find a way to precisely place panels, and the VLN came in really handy for them.” He adds, “It sped up the operation and allowed them to place those panels with up to one degree of precision.”
The Vita Load Navigator lifts a Wolff tower crane jib into place
IMAGE: WOLFFKRAN
Traditional methods rely on taglines to control loads, but at extreme heights, taglines become ineffective, Rosenberger tells ICON. “If you’re really high up – 38 storeys, 40 storeys – you can’t get any control out of a tagline. If anything, you’re going to cause a hazard.” Wind is a constant challenge in crane operations, and stopping work due to excessive wind can cause significant delays. In California, a contractor using the VLN reported significant efficiency improvements. “They were working on a parking garage and dealing with high winds on a daily basis,” Rosenberger details. “The VLN enabled them to keep working when other subcontractors on-site had to shut down. They were the only ones out of 50 subcontractors who kept working daily, allowing them to stay on schedule and save a lot of money.”
The technology also improves safety in tower crane assembly. “The way you build a tower crane is very critical – it’s all critical lifting,” Rosenberger says.
The Karlatornet high-rise in Gothenburg while it was under construction. The now finished structure is the tallest in Scandinavia
iMAGE: ADOBE STOCK
Major high-rise project
Last year was a busy year for project starts and project completions in the high-rise construction sector, with major schemes reaching significant milestones.
One of these was Karlatornet in Gothenburg, Sweden, a 74-storey mixed-use skyscraper reaching 246m; the tallest building in the Nordics.
The tower houses 611 residential units, alongside hotel accommodations, office spaces, and retail areas.
Designed by Skidmore, Owings & Merrill (SOM) and developed by Serneke Group AB, construction commenced in 2018, with the building topping out in June 2023 and official completion achieved in autumn 2024. Aarsleff was the general contractor.
A notable aspect of Karlatornet’s construction was the challenging ground conditions, which required innovative foundation solutions, including the use of over 12,000m3 of highstrength concrete for the 58 cast-in-place concrete piles supporting the structure.
The 1000m tower, centre frame, in Chicago, US, opened in June 2024
IMAGE: 1000M APARTMENTS
Kim Bräuner Rasmussen, project manager at Aarsleff, notes drilled shaft piers were used in construction, which started 70m below ground level through a 40-50m-thick layer of clay (along with cohesionless soil and bohus granite); an unusual solution for Swedish constructors.
“We have worked with similar technology in Denmark earlier, though in much smaller dimensions,” Rasmussen says. “Here in Gothenburg, each cast-in-place pile measures two meters in diameter and is capable of carrying a load of around 4,500 tonnes individually.” The project cost is approximately US$525 million to construct.
Mixed-use towers
The Couture – located in Milwaukee, Wisconsinm, US – is a 44-storey mixed-use tower standing at 164m, making it the tallest residential building in the state.
The development includes 322 high-end apartments, 4,645m2 of restaurant and retail space, and a 1,100-space parking structure. The building also functions as a multimodal transit hub, integrating a streetcar station for The Hop streetcar and a bus rapid transit station for the Milwaukee County Transit System.
Designed by RINKA and developed by Barrett Lo Visionary Development, construction began in June 2021 and was completed in early 2024, with J.H. Findorff & Son as general contractor, Thornton Tomasetti as engineer and GRAEF as civil engineer. It cost around $200 million to construct.
Peri Formwork Systems used several of its products on the build, including the ACS Core 400 self-climbing formwork system, Maximo and Trio for shear walls, and Skytable for the cast-in-place floors.
“Crews used 3,066m2 of Garagedeck to form the beam and slab post-tensioned garage and complete the parking levels,” Peri notes. “Garagedeck is engineered for the US market and delivers a cost-effective structure with no design limitations in superior quality.” The Couture’s cladding system utilised the same forms across all stories, which leant itself to precast concrete construction; 708 precast forms were used on the project.
The Octagon tower in Birmingham, UK
IMAGE COURTESY PARADISE BIRMINGHAM
Turning our attention back to Europe, and the Octagon: a 49-storey residential tower standing 155m tall in Birmingham, UK. The building comprises 370 build-to-rent apartments. Construction began in March 2022, with completion anticipated this year. Midgard serves as the main contractor. It’s expected to cost just more than $119 million to build and is part of a grander $1.3 billion development programme in Birmingham.
The tower’s namesake comes from its unique octagonal design, which is believed to be a world’s tallest of its type.
High-rise market looking up
These projects are certainly evidence the residential high-rise market is strong and growing. While the same issues plague highrise that does general construction, it’s clear OEMs and contractors are adept at finding new products and solutions to navigate the environment.
Also, while most high-rises today are likely to remain residential, there’s always a possibility that the troubled office and commercial highrise segments could rebound in the coming years. Regardless, cities are expanding and populations growing, so expect high-rise specialists to stay busy this year and next. iC
Wolff 8095 Compact saddle jib tower crane
IMAGE: WOLFFKRAN
NEW 900 TONNE WOLFF TOWER CRANE
Manufacturer Wolffkran in Germany announced a new 900 tonne-metre rated model in its Compact series of low top tower cranes.
The Wolff 8095 Compact is the first saddle jib model from Wolff in the 900 tonne-metre class. The first showing of this new high-capacity model will be at the Bauma trade show in Munich, Germany, from 7 to 13 April 2025.
“With the new Wolff 8095 Compact, we have succeeded in designing our largest trolley jib crane to date with an impressive lifting capacity. Thanks to its tower top section, which is about six metres shorter than the cross-jib version, it is very compact and economical,” says Dr Mohamed Abouelezz, Wolffkran head of business development and product management.
Two versions are available, with lifting capacities of 25 and 40 tonnes. The 8095.25 lifts 25 tonnes on two falls of rope and 10.5 tonnes at the end of an 80m jib using the Wolff Boost function.