Rail Mounted Gantry Crane Key Features & Specifications

• 1. Robust Structural Design:

  • Fabricated from high-grade steel (S355JR or equivalent) for exceptional strength and longevity.

  • Optimized box-girder or truss design minimizes dead weight while maximizing rigidity and resistance to dynamic loads and wind forces.

  • Corrosion-resistant coatings ensure durability in harsh maritime and industrial environments.

• 2. Precision Rail Guidance & Travel:

  • Moves longitudinally on dedicated, precisely aligned ground rails spanning the stacking block.

  • Heavy-duty end carriages with double-flanged wheels ensure smooth, stable travel and prevent derailment.

  • High-torque AC frequency-controlled drive motors provide smooth acceleration, deceleration, and precise positioning (± 50mm).

  • Automatic rail lubrication systems minimize wear and friction.

• 3. High-Performance Hoisting & Trolley:

  • Powerful AC or DC hoist motors with regenerative braking for controlled lifting and lowering.

  • Wide lifting capacity range: Standard models: 30.5t, 40t, 50t, 60t | Heavy Lift options: Up to 100t+ (under spreader).

  • High lifting speeds (up to 50-70 m/min empty, 25-35 m/min laden) and lowering speeds.

  • Cross-trolley traverses the crane girder(s) transversely using frequency-controlled drives for precise container placement.

  • Trolley travel speeds typically 50-70 m/min.

• 4. Advanced Spreader System:

  • Compatible with various ISO container sizes (20ft, 40ft, 45ft, HC, OT, etc.).

  • Options: Manual, Semi-Automatic Twistlock (SATL), or Fully Automatic Twistlock (FATL) systems.

  • Telescopic spreaders for handling mixed container heights efficiently.

  • Optional features: Weighing system, container position scanning, reefer monitoring.

• 5. Superior Control & Automation:

  • Operator Cab: Ergonomically designed, air-conditioned cabin mounted on the trolley or portal leg, offering optimal visibility with 360° cameras and proximity sensors. Equipped with intuitive HMI controls and diagnostic systems.
  • Remote Operation Station (ROS): Optional remote control centers allow operators to control multiple RMGs from a central location, enhancing safety and ergonomics.
  • Full Automation: Integration capability with Terminal Operating Systems (TOS) for fully automated, unmanned operation (ARMG – Automated Rail Mounted Gantry), guided by GPS, laser scanners, and optical character recognition (OCR).

• 6. Comprehensive Safety Systems:

  • Redundant overload protection (mechanical and electronic).

  • Multi-level anti-collision systems (crane-to-crane, crane-to-endstops, crane-to-ground equipment).

  • Emergency stop systems (E-stops) at cab, ground level, and remote stations.

  • Storm securing devices (rail clamps, wind brakes).

  • Advanced anemometers for automatic wind speed limitation/shutdown.

  • Personnel protection zones (laser scanners, safety mats).

  • Fire detection and suppression systems.

• 7. Power Supply Options:

  • Conductor Bar (Cable Reel): Most common, providing continuous power supply via sliding collector shoes along the crane runway.
  • Diesel Generator: For yards without fixed power infrastructure or as a backup.
  • Hybrid Systems: Combining grid power with battery storage or diesel generators for peak shaving and energy efficiency.

Rail Mounted Gantry Crane (RMG) – Technical Parameter Table

Notes & Customization:

• 1. Hybrid Power: Combines grid power with battery storage for peak shaving and backup.
• 2. Lifting Capacity: Standard for ISO containers; heavy-lift models for project cargo.
• 3. Automation: ARMG (Automated RMG) requires integrated Terminal Operating System (TOS).
• 4. Structural Design: Fabricated from S355JR steel; corrosion-resistant coating standard.
• 5. Customization: All parameters (span, height, speed, power) can be engineered to site-specific needs.

Rail Mounted Gantry Crane Operational Advantages

• 1. Maximized Yard Density: Enables stacking containers 6+ wide and 5+ high within a single rail span, optimizing valuable terminal real estate.
• 2. High Productivity: Fast cycle times (pick-up and stack/drop-off) due to independent hoist, trolley, and gantry movements.
• 3. Exceptional Reliability & Uptime: Robust design and high-quality components ensure continuous operation with minimal downtime. Easy maintenance access points.
• 4. Enhanced Safety: Superior stability on rails compared to RTGs, combined with comprehensive electronic safety systems, creates a safer working environment.
• 5. Reduced Ground Traffic: Minimizes the need for internal trucks within the stacking block, reducing congestion and potential accidents.
• 6. Lower Operating Costs: Energy-efficient drives, reduced tire wear (compared to RTGs), and potential for automation lead to significant long-term cost savings.
• 7. Environmental Benefits: Potential for electric operation (zero local emissions), lower noise levels, and reduced diesel consumption compared to RTGs.

Installation & Commissioning

• 1. Expert Project Management: Our experienced team manages the entire process from site preparation guidance to final handover.
• 2. Modular Construction: Major components (legs, girders, end carriages) are pre-fabricated and pre-tested off-site for efficient assembly and minimized on-site disruption. Typical on-site installation duration: 4-8 weeks depending on complexity and site conditions.
• 3. Precision Rail Installation: Critical to performance. We provide specifications and oversight for accurate rail alignment, foundation work, and grouting.
• 4. Rigorous Testing & Commissioning: Comprehensive functional testing (FAT at factory, SAT on-site) under load and no-load conditions to ensure all systems (mechanical, electrical, control, safety) meet design specifications and operational requirements. Includes calibration of sensors and positioning systems.
• 5. Operator & Maintenance Training: Comprehensive training programs for crane operators, maintenance technicians, and supervisors to ensure safe, efficient, and optimal utilization.

Maintenance & Service Support

• Predictive & Preventive Maintenance Programs: Tailored service plans utilizing condition monitoring (vibration analysis, thermography, oil analysis) to maximize uptime and component lifespan. Remote diagnostics capabilities.

• Global Spare Parts Network: Strategically located warehouses ensure rapid availability of genuine OEM spare parts worldwide. Online parts catalogues and ordering.

• 24/7 Technical Support: Access to expert engineering support via phone, email, or remote connection for troubleshooting and guidance.

• Field Service Engineers: Certified technicians available for scheduled maintenance, emergency repairs, and major overhauls.

• Lifecycle Management & Modernization: Services to extend crane life through component upgrades, control system modernization, and performance enhancement retrofits.

Industry Trends & Our Innovation

• 1. Increased Automation Adoption: Seamless integration with Terminal Operating Systems (TOS) for fully automated stacking and retrieval (ARMG), optimizing flows and reducing labor costs. Advanced features like automatic truck handling.
• 2. Enhanced Energy Efficiency: Focus on regenerative drives, energy recovery systems, LED lighting, and optimized power management software. Hybrid power options gaining traction.
• 3. Data-Driven Operations: IoT sensors collect operational data (cycle times, energy consumption, component health) for performance analytics, predictive maintenance, and continuous improvement.
• 4. Higher Stacking & Wider Spans: Designs evolving to handle 7-wide, 1-over-6 high stacking configurations to maximize yard density in constrained spaces.
• 5. Improved Ergonomics & Safety: Continued development of remote operating stations with immersive visualization (VR/AR), advanced collision avoidance AI, and enhanced personnel detection systems.
• 6. Sustainability Focus: Drive towards full electrification, reduced noise emissions, and solutions supporting “Green Port” certifications.

Project Approach & Customization

• 1. Needs Analysis: In-depth consultation to understand your specific throughput targets, yard layout constraints, container mix, operational model (manual/remote/auto), and future expansion plans.
• 2. Tailored Engineering: Every RMG system is engineered to order. We optimize span, lifting height, lifting capacity, speed profiles, and control/automation level based on your unique requirements.
• 3. Seamless Integration: Expertise in integrating the RMG system with your existing or planned TOS, gate systems, truck handling processes, and other terminal equipment.
• 4. Lifecycle Cost Optimization: Designing for reliability, maintainability, and energy efficiency to deliver the lowest Total Cost of Ownership (TCO) over the crane’s operational life.