In today's construction and maintenance sectors, efficiency at height is about far more than reach alone. Contractors are increasingly looking for equipment that can maximise productivity, minimise site disruption and, above all, improve safety.

It is a challenge that has driven the continued development of rotating telehandlers, and one that the latest Merlo ROTO range has been specifically designed to address. Combining the functions of a telehandler, crane and mobile elevated work platform in a single machine, the ROTO has become one of the most versatile tools available for working at height.

Unlike a conventional telehandler, the ROTO's rotating turret allows operators to work around the machine without repositioning the chassis. Depending on the model, rotation ranges from 400 degrees through to 600 degrees, while the flagship machines in the upcoming ROTO 60 Series offer continuous rotation. The result is a significantly larger working area from a single setup position, reducing downtime and improving productivity on busy construction sites where space is often at a premium.

Built for Modern Construction Sites

For contractors involved in steel erection, cladding installation, roofing, glazing, industrial maintenance or infrastructure projects, the benefits become even more apparent when the machine is equipped with a hydraulic personnel basket. Once stabilised, operators can elevate, extend and rotate the platform precisely into position without repeatedly lowering the basket and repositioning the machine. Not only does this save valuable time, it also reduces ground movements, site congestion and potential safety risks.

A key advantage of the ROTO concept is its ability to combine access and handling tasks within a single machine. By changing attachments, contractors can move seamlessly between lifting materials, placing loads and carrying out work-at-height operations, maximising utilisation and reducing fleet requirements. Compatibility with a wide range of attachments, including forks, winches, hooks and work platforms, gives the ROTO exceptional flexibility across multiple applications.

The New Roto 60 Series
The next generation of machines takes this versatility even further. Previewed by Merlo at BAUMA, the new ROTO 60 Series introduces increased lifting capacities, enhanced machine performance and an array of intelligent electronic functions designed to improve both efficiency and operator confidence.

The new generation features a "Set Point" function that automatically returns the boom to a memorised position, helping speed up repetitive work cycles while reducing operator fatigue. Meanwhile, Cartesian movement controls automatically maintain a vertical trajectory when raising or lowering an attachment and a horizontal trajectory during boom extension and retraction, improving precision when positioning personnel or materials at height.

Another significant development is the introduction of load-chart simulation technology. Before beginning a lift, operators can simulate various operating conditions, including attachment selection, load weight and stabiliser position, to determine whether a task can be completed safely and efficiently. By providing greater visibility of machine capability before work commences, the system helps improve both planning and site safety.

Intelligent Control at Height
Perhaps the most notable advancement for working-at-height applications is the new radio remote-control system. Featuring a patented ergonomic design and integrated LCD display, the latest controller provides operators with a far greater level of machine information directly in their hands.

Real-time feedback on machine status allows operators to maintain complete control while working remotely from the ground or directly from the attached platform. In the event of a potentially unsafe operating condition, the display background changes colour to alert the operator and facilitate safe corrective movements, a feature unique to the new generation ROTO.

The benefits extend beyond control of the boom and attachment functions. The new system also enables remote stabilisation and even machine repositioning at speeds of up to 5km/h. This allows operators to manoeuvre the machine from a safe vantage point or directly from the platform, maintaining a clear view of the task while minimising interruptions and increasing overall site efficiency.

Coming to UK in 2027

Scheduled to arrive in the UK during 2027, the new Merlo ROTO 60 Series (six tonne capacity with lift heights of 22m, 27m, 30m and 35m) represents the next stage in the evolution of working-at-height equipment. Combining continuous rotation, advanced electronic assistance systems and industry-leading remote-control technology, it promises to deliver even greater productivity, safety and versatility for contractors looking to do more from a single machine setup. For operators working at height, the future of access has never looked more capable.

Preview the all-new ROTO range at Bauma 2025

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