Mobile Container Gantry Crane 30t

 

 

What is a Mobile Container Gantry Crane?

It is a self-propelled, high-capacity gantry crane that travels on rubber tires. Its key characteristic is its ability to straddle multiple rows of containers (and the trucks and trailers that move between them) and to be quickly repositioned around the storage yard as needed. They are a common sight in port terminals, intermodal yards, and depots.

 

Comparison: Mobile (RTG) vs. Rail-Mounted (RMG) Gantry Crane

Feature	Mobile (RTG)	Rail-Mounted (RMG)
Mobility	High - moves freely on rubber tires	Low - confined to fixed steel rails
Infrastructure	Requires only a paved surface	Requires extensive fixed rail track foundation
Flexibility	High - easily redeployed	Low - fixed to one stacking area
Cost	High purchase price, lower infrastructure cost	Very high infrastructure cost
Stacking Height	Typically 4-5 high over 5-6 lanes	Can be higher (5-6+ high) over 8+ lanes
Efficiency	Good	Excellent (higher speed, no steering needed)
Environment	Diesel emissions & noise (unless electric)	Electric, cleaner, and quieter

 

Rated Loading Capacity：5 ton, 10 TON, 100 ton, customized, 16/3.2 ton, 20/5 ton, 32/5 ton, 50/10 ton

Max. Lifting Height：40m, customized

Span：35m or clients' demands

Warranty：1 Year

Weight (KG)：20000 kg

Core Components：PLC, Engine, Bearing, Gearbox, Motor, Pressure vessel, Gear, Pump

Control way：Cab, wireless remote control or customized

 

 

1. Structural System

This is the crane's massive skeleton, designed to withstand immense loads and forces.

Main Girder / Bridge: The primary horizontal beam that spans the width of the container stacks. It is a robust, welded box girder structure strong enough to support the trolley, hoist, and a fully laden container.

Legs (Port and Starboard): Two A-frame or portal-style legs support each end of the main girder. They provide the height needed to stack containers and are designed for strength and stability.

End Frames / End Trucks: The lower part of each leg that houses the wheels, drive motors, steering systems, and spreader bar for the tires. This is the "engine room" for the crane's movement.

 

 

2. Mobility & Propulsion System

This system gives the crane its name and defining feature: the ability to move on rubber tires.

Rubber Tires: Typically 8 large, heavy-duty, pneumatic tires (4 per end truck). These distribute the crane's enormous weight and allow it to travel on paved surfaces.

Drive Motors: Powerful electric motors (usually one per wheel or axle) provide the torque to move the massive crane. These are typically powered by a generator.

Steering System: A complex hydraulic or electromechanical system that controls the angle of the wheels. Key steering modes include:

90° Steering: Wheels turn perpendicular to the crane for "crabbing" side-to-side.

Coordinated Steering: For turning corners.

Parallel Steering: For straight-line travel.

Braking System: Multi-redundant systems including service brakes, emergency brakes, and parking brakes to ensure safety under all conditions

3. Lifting & Handling System

The core system responsible for actually moving the containers.

Trolley: The frame that runs on rails along the top of the main girder. It carries the hoist machinery and the spreader.

Trolley Drive: The motor, gears, and wheels that propel the trolley back and forth across the span of the crane.

Hoist Unit: The powerful winch system that raises and lowers the load. It consists of:

Hoist Motors: High-torque motors that drive the drums.

Wire Rope Drums: Large drums that spool the high-strength steel wire ropes.

Wire Ropes: Run from the drums, over sheaves on the trolley, down to the spreader.

Brakes: Fail-safe brakes that hold the load securely.

Spreader: The intelligent, specialized device that locks onto the container. It is the interface between the crane and the load.

Twistlocks: Hydraulically or electrically operated pins that engage into the corner castings of a shipping container.

Telescopic Mechanism: Allows the spreader to adjust its length to handle 20ft, 40ft, 45ft, and other standard container sizes.

Sway Control: Systems to minimize container swing during movement.

4. Power System

How the crane generates and manages the immense energy required for its operations.

Diesel Generator Set: A large, onboard diesel engine that drives an electrical generator. This is the most traditional power source, creating electricity for all the crane's drives and systems.

Electric RTG (eRTG) System: A growing trend. Instead of a diesel generator, the crane connects to the terminal's electrical grid via a Cable Reel System or Conductor Bar (often mounted on the side of the leg). This eliminates emissions and reduces noise and operating costs.

Hybrid System: Some cranes use a combination: a smaller diesel generator paired with a large battery bank that handles peak power demands, reducing fuel consumption.

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5. Control & Operator System

The nerve center of the crane.

Operator's Cab: Mounted high on one leg for optimal visibility over the container stack. It is soundproofed, air-conditioned, and equipped with ergonomic controls.

Control Interfaces:

Joysticks: For precise control of the hoist, trolley, and gantry travel.

Screens: Displaying load weight, spreader status, steering mode, and camera feeds.

Programmable Logic Controller (PLC): The computer that acts as the crane's brain, processing all operator commands and managing safety interlocks and automation sequences.

Cameras & Sensors: A network of cameras provides views of the spreader, tires, and blind spots. Sensors monitor everything from load weight and wind speed to the position of the twistlocks.

6. Safety Systems

Critical components that protect the load, the crane, and personnel.

Anti-Collision System: Uses radar or laser sensors to detect obstacles or other cranes and can automatically stop movement to prevent collisions.

Load Moment Indicator (LMI): Monitors the load weight and warns the operator if they approach or exceed the crane's rated capacity.

Anemometer: Measures wind speed and will alarm or shut down operations if speeds become dangerous.

Limit Switches: Prevent the trolley and hoist from moving beyond their safe physical limits.

Emergency Stop (E-Stop) Buttons: Located at multiple points to cut all power immediately.

Sketch

 

 

 

Advantages of Mobile Container Gantry (RTG) Cranes

The advantages of RTGs stem from their unique combination of mobility and high stacking capability.

1. Exceptional Mobility and Flexibility

Free Roaming: Unlike rail-mounted gantries (RMGs), RTGs can drive anywhere within the terminal on rubber tires. This allows terminal managers to easily redeploy cranes to different yards or stacking areas based on changing demand, ship schedules, or yard congestion.

Adaptable Layouts: Terminals are not locked into a fixed track infrastructure. The stacking pattern (e.g., number of containers wide) can be modified more easily.

2. High Stacking Density

RTGs can typically stack containers 5-wide and 4-5 high (depending on the model). This makes very efficient use of valuable real estate within a port or yard, maximizing storage capacity.

3. Versatility in Operations

Direct Truck Interaction: RTGs can directly load and unload trucks and terminal tractors without requiring a separate piece of equipment like a top loader. This streamlines the transfer process.

Multi-Modal Handling: They are equally effective at handling containers that arrive or depart by ship, train, or truck, making them a central tool for intermodal terminals.

4. Lower Initial Infrastructure Cost

While the crane itself is expensive, it requires only a strong, paved surface to operate on. This is significantly cheaper than installing the extensive fixed rail tracks and foundations required for Rail-Mounted Gantry (RMG) cranes.

5. Easy Integration and Relocation

They can be added to a terminal's fleet incrementally as business grows.

If needed, they can even be driven to a different part of the terminal or, with special permits, to a completely different facility.

6. Evolution towards Eco-Friendly Operation

Diesel-Electric to Electric (eRTG): Traditional RTGs use a diesel generator. The industry is rapidly shifting to eRTGs that can be powered by:

Cable Reels: Connecting to the grid via a long, retractable cable.

Conductor Bars: Drawing power from an electrified rail system along the stack.

Battery Hybrid or Full Electric: Using large battery packs to eliminate emissions entirely.

This shift drastically reduces fuel costs, greenhouse gas emissions, and noise pollution.

 

Applications of Mobile Container Gantry (RTG) Cranes

The application of RTGs is highly specialized to the container handling industry, but within that, they are incredibly versatile.

1. Port Container Terminals (The Primary Application)

Container Yard Stacking: This is their core function. RTGs are the workhorses of the storage yard, stacking containers discharged from ships by quay cranes.

Receiving and Delivery: They are used to load containers onto trucks for delivery to customers and to receive containers from trucks arriving for export.

Inter-Stack Transfer: Moving containers within the yard to organize them for efficient loading onto ships or trains.

2. Intermodal Rail Terminals

Transfer Operations: RTGs are used to lift containers on and off railcars.

Rail Yard Storage: They stack containers near the rail siding before loading or after unloading.

3. Container Depots and Storage Facilities

Off-Dock Facilities: Used for medium-to-long-term storage of containers, empty container repair, and maintenance.

Container Freight Stations (CFS): Handling containers for stuffing (loading) and stripping (unloading) goods.

4. Specialized Industrial Applications

In large industrial complexes that receive or ship massive volumes of containerized goods (e.g., large manufacturing plants).

 

 

1. Design and Engineering

Detailed Engineering: Develop detailed engineering drawings and specifications, including the main beam, hoist, trolley, end carriages, and other components.

Simulation and Modeling: Use computer-aided design (CAD) and simulation tools to model the crane's performance and optimize its design.

2. Material Selection

Material Specifications: Select high-quality materials that meet the requirements for strength, durability, and heat resistance. Common materials include high-strength steel, alloys, and specialized coatings.

Procurement: Source materials from approved suppliers, ensuring they meet the necessary quality and certification standards.

3. Component Fabrication

Cutting and Shaping: Cut and shape raw materials into the required components, such as beams, columns, and brackets. This may involve processes like plasma cutting, laser cutting, and machining.Welding and Assembly: Weld components together to form the crane's structural elements. This includes welding the main beam, end carriages, and other load-bearing parts.

4. Assembly

Sub-Assembly: Assemble individual components, such as the hoisting system, trolley, and end carriages, into sub-assemblies. This involves fitting parts together and ensuring proper alignment.Main Assembly: Combine sub-assemblies to construct the complete crane structure. This includes mounting the hoist and trolley on the main beam, attaching the end carriages, and installing the control systems.

5. Integration of Systems

Electrical Systems: Install electrical components, including motors, control panels, wiring, and sensors. Ensure that the crane's electrical systems are properly integrated and tested.

Control Systems: Implement and configure control systems, such as programmable logic controllers (PLCs), remote controls, and safety devices. Verify that the control systems function correctly and are calibrated.

6. Testing and Quality Assurance

Pre-Operational Testing: Conduct pre-operational tests to check the crane's functionality, including load testing, operational testing of the lifting and traveling mechanisms, and control system checks.

Safety Testing: Verify that safety features, such as limit switches, alarms, and emergency stops, are working correctly and meet safety standards.

Inspection: Perform a detailed inspection of the crane's structure and components to ensure compliance with design specifications and quality standards.

7. Final Adjustments and Calibration

Fine-Tuning: Make any necessary adjustments to optimize the crane's performance and ensure smooth operation. This may include calibrating sensors, adjusting controls, and fine-tuning the lifting system.

Documentation: Prepare and review documentation, including operation manuals, maintenance guides, and safety instructions.

8. Delivery and Installation

Transport: Arrange for the transport of the crane to the installation site, ensuring that it is handled and shipped safely to prevent damage.

Installation: Oversee the installation of the crane at the customer's facility, including assembly, alignment, and connection to power sources and control systems.

Training: Provide training for operators and maintenance personnel to ensure they are familiar with the crane's operation and safety procedures.

9. Commissioning and Handover

Commissioning: Conduct final commissioning tests to verify that the crane operates correctly under real-world conditions and meets performance specifications.

Handover: Officially hand over the crane to the customer, providing all necessary documentation, including certificates of compliance, warranty information, and maintenance schedules.

 

 

 

Material Inspection

Quality Inspection: Strict quality inspection is carried out on the purchased raw materials to ensure that they meet the design requirements and national standards.

Material Storage: Qualified materials are stored according to classification to prevent corrosion or damage.

Cutting and Forming

Steel Cutting: Use plasma cutting, laser cutting or flame cutting and other technologies to cut the steel according to the size of the design drawing.

Forming Processing: Form the steel plate through bending, rolling, welding and other processes to manufacture the main beam, end beam and other structural parts.

Welding

Component Welding: The cut and formed steel parts are welded into the main structures such as the main beam, end beam and trolley. The welding process needs to be strictly controlled to ensure the structural strength and welding quality.

Weld Inspection: Use non-destructive testing technology (such as ultrasonic testing, radiographic testing) to inspect the welds to ensure that there are no cracks or other defects.

Machining

Precision Machining: Precision machining is performed on the key components of the crane, such as wheel sets, bearing seats, pulleys, etc., to ensure their dimensional accuracy and surface quality.

Assembly of the whole machine

General assembly: On the basis of pre-assembly, the overall assembly of the crane is carried out, including the final installation of the main beam, end beam, lifting mechanism, walking mechanism, etc.

Commissioning and testing

Under dynamic conditions, the operating performance of the crane is tested, including the testing of lifting, walking, steering and other functions. The overall size of the assembled bridge crane is checked to ensure that all dimensions meet the design requirements.

Spraying and anti-corrosion treatment

Surface treatment Rust removal: Rust removal on the surface of the crane, common methods include sandblasting, pickling, etc. Primer spraying: Spray anti-corrosion primer on the treated surface to prevent metal oxidation and corrosion. Topcoat spraying Color spraying: Spray topcoat according to customer requirements or industry standards to give the crane a protective and decorative effect. Marking: After spraying, mark the crane's identification information in accordance with the specifications, such as model, rated load, etc.

Factory and installation

Packaging and transportation

Packaging protection: Protectively package the key components of the crane to prevent damage during transportation. Transportation arrangement: According to the equipment size and transportation conditions, select a suitable transportation method to transport the crane to the customer's site.

Acceptance and delivery

Customer acceptance

On-site acceptance: The customer conducts on-site acceptance of the crane according to the contract requirements and technical specifications to check the performance and quality of the equipment.

Problem rectification: If any problems are found, the manufacturer needs to rectify them in time to ensure that the equipment fully meets the customer's requirements. Delivery and use Operation training: The manufacturer usually trains the customer's operators to ensure that they can operate the crane correctly and safely.

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