Rubber Tyred Gantry Crane

 

What is a Rubber Tyred Gantry Crane?

Structure: A-frame or box-type gantry supported by rubber tyres.

Mobility: Moves freely on pneumatic tires, no need for fixed rails.

Lifting Mechanism: Often uses a hoist trolley or spreader for container handling.

Drive System: Typically powered by diesel engine, electric motor, or hybrid drive.

 

Advantage	Description

High Mobility

Can move across multiple work areas without the need for rails.

Easy to Deploy

No foundation or track installation needed-reduces setup time and cost.

Suitable for Uneven Terrain

Can operate on asphalt, concrete, or gravel surfaces.

Flexible Operation

Ideal for temporary or shifting work zones (e.g., precast yards).

Multiple Power Options

Can be diesel, electric, or hybrid, depending on application and emission requirements.

Heavy Lifting Capability

Lifting capacities often range from 10 tons to 200+ tons.

Customizable Design

Adjustable span, lifting height, and hoisting mechanism available for specific jobs.

 

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 Components
A. Gantry Frame (Main Girder & Legs)
The primary steel structure that spans the container stacks.

Includes two vertical legs supporting a horizontal girder.

Designed to withstand heavy loads (typically 40–50 tons per container).

B. Boom (Cantilever)
Extends beyond the legs to allow overreach for container stacking.

Some RTGs have retractable booms for better maneuverability.

C. Trolley & Hoist System
Trolley: Moves horizontally along the girder for container positioning.

Hoist Mechanism: Includes wire ropes, drums, and motors for lifting containers.

Spreader (Twist Lock System): Attaches to containers (adjustable for 20ft, 40ft, 45ft).

 

 

2. Mobility & Steering System
A. Rubber Tires & Wheels
Typically 4, 8, or 16 tires (depending on load capacity).

Made of high-grade rubber to support heavy loads (up to 100+ tons).

Some models use split wheels for easier maintenance.

B. Drive & Steering Mechanism
Diesel or Electric Drive Motors: Power the wheels for movement.

Steering System: Allows 90° crab steering for tight turns.

Hydraulic or Electric Steering Control: Ensures precise movement.

C. Braking System
Service Brakes: For normal stopping.

Emergency Brakes: For sudden halts.

Regenerative Braking (in hybrid/electric RTGs): Recovers energy during deceleration.

3. Power System
A. Power Source
Diesel Engine (Traditional RTG): Powers hydraulic/electric systems.

Electric RTG (ERTG): Uses cable reels, sliding contacts, or supercapacitors for grid power.

Hybrid RTG: Combines diesel and electric power for efficiency.

B. Energy Recovery Systems
AFE (Active Front End) Rectifiers: Feed regenerated energy back into the grid.

Supercapacitors/Battery Storage: Stores braking energy for reuse.

 

4. Control & Automation Systems
A. Operator Cabin
Located on the gantry for visibility.

Equipped with joysticks, touchscreens, and safety controls.

B. Automation Features
DGPS/RTK Positioning: For automated container stacking.

Anti-Sway System: Stabilizes load movement.

Tire Pressure Monitoring (TPMS): Alerts for low pressure or damage.

C. Safety Systems
Anti-Collision Sensors: Prevents crashes with other RTGs.

Wind Speed Monitor: Stops operations in high winds.

Emergency Stop (E-Stop): Instantly halts all functions.

 

5. Auxiliary Systems
A. Hydraulic System
Powers steering, brakes, and spreader adjustments.

Includes pumps, valves, and actuators.

B. Lighting & Signals
LED Work Lights: For night operations.

Warning Alarms & Beacons: For safety alerts.

C. Cooling & Ventilation
Radiators & Fans: Prevent overheating (critical for diesel RTGs).

HVAC in Cabin: Ensures operator comfort.

 

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6. Optional Upgrades
Automated Stacking (AS-RTG): Fully remote-controlled operation.

Solar Panels: For auxiliary power in hybrid models.

LIDAR/Camera Vision: For obstacle detection.

Component	Function
Main Girder	Supports trolley and load
Legs	Connect girder to wheels, bear vertical loads
Hoisting Trolley	Lifts/lowers and moves load crosswise
Rubber Tyred Wheels	Enable mobile ground movement
Drive System	Powers the crane's mobility
Electrical System	Feeds power to all functions
Operator Controls	Manages crane operations (manual or remote)
Safety Devices	Ensure secure and reliable use

SKETCH

 

 

 

 

Mobility & Flexibility
Rubber tires allow free movement across container yards without fixed tracks, enabling transpositioning (relocating between different stacking blocks).
90° crab steering and 4/8/16-wheel configurations provide excellent maneuverability in tight spaces.
Unlike Rail-Mounted Gantry Cranes (RMGs), RTGs do not require permanent rail infrastructure, reducing initial investment costs.

 

Energy Efficiency & Environmental Benefits
Hybrid & Electric RTGs (ERTGs) reduce fuel consumption by 25% or more by integrating:
Lithium battery systems (replacing diesel generators).
Regenerative braking, feeding energy back into the grid via Active Front End (AFE) rectifiers.
Supercapacitors for short-term energy storage.
Lower emissions compared to traditional diesel-powered RTGs, aligning with green port initiatives.

 

Cost-Effectiveness
Lower infrastructure costs (no need for rails).

Reduced maintenance compared to rail-mounted systems.

Adaptable to automation, reducing labor costs (e.g., GPS-guided stacking).

 

Automation & Safety Features
Remote control & autonomous operation using DGPS, LIDAR, and AI.

Anti-collision systems and wind speed monitoring enhance operational safety.

Tire Pressure Monitoring Systems (TPMS) prevent accidents due to tire failures.

 

RTG cranes are extremely versatile and used in a wide range of industries that require efficient outdoor material handling with high mobility.

1. Port & Container Terminals
Stacking, loading, and unloading shipping containers.

Operates in container yards, ICD terminals, and intermodal stations.

2. Precast Concrete Yards
Lifting and transporting precast bridge segments, tunnel rings, slabs, beams, and columns.

Excellent for large-scale infrastructure projects like highways and railways.

3. Steel & Pipe Yards
Handling steel coils, structural steel, long pipes, and heavy metal plates.

Often used in manufacturing plants and storage depots.

4. Shipbuilding & Boat Yards
Lifting and positioning ship parts, engines, or even entire boat hulls.

Ideal for modular assembly areas or dry docks.

5. Construction Sites
Transporting modular units, containers, or construction materials.

Works well in temporary, rough, or spread-out job sites.

6. Wind Power & Energy Industry
Moving turbine components, generators, or heavy machinery.

Useful at assembly sites or logistics bases.

 

 

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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