Impact of Lifting Height Requirements on Rubber Tyred Gantry Crane Design

Rubber tyred gantry (RTG) cranes are widely used in container terminals, logistics yards, manufacturing facilities, steel coil yards, precast concrete plants, and other environments that require flexible, mobile lifting solutions. Among all design parameters, lifting height—the maximum vertical distance the spreader or hook must reach above ground—has a profound influence on the RTG’s structural configuration, performance characteristics, cost, and long-term operational suitability. As container stacks grow taller and industrial loads become larger or more complex, understanding how lifting height affects RTG crane design becomes essential for selecting the correct equipment.

This article explores how lifting height requirements shape rubber tyred gantry crane engineering, including structural design, stability, motor selection, trolley travel, safety systems, and cost implications.

1. The Role of Lifting Height in RTG Crane Applications

The required lifting height varies depending on the industry and material handling scenario:

• Container terminals: RTG cranes often need to stack containers 4+1, 5+1, or even 6+1 high. Each stacking tier adds around 2.6–2.9 meters to the lifting height.

• Precast concrete yards: Height may vary widely depending on the size of beams, slabs, or wall panels.

• Steel yards: Coils, billets, or long steel products may require additional clearance for safe lifting.

• Manufacturing facilities: Large machinery or bulky assemblies necessitate custom height clearance.

Because these applications differ significantly, the lifting height is one of the first parameters engineers analyze during RTG design.

2. Structural Implications of Increased Lifting Height

2.1 Higher Columns and Main Beams

A higher lifting height requires taller portal frames, which directly impacts:

• Column strength and thickness

• Beam cross-section and torsional rigidity

• Welded joints and connection reinforcement

• Overall frame weight and distribution

Taller structures are more susceptible to lateral loads (wind and sway), so engineers typically increase the size of the columns or use higher-grade steel to maintain structural integrity.

2.2 Increased Gantry Width and Stability

As lifting height increases, the mobile gantry crane center of gravity is raised, reducing stability. To counter this, designers might:

• Widen the gantry to distribute weight

• Increase wheel spacing

• Enhance the chassis and load-bearing components

• Optimize the geometry for better load path efficiency

Stability is especially important for mobile RTGs operating on rubber tyres without fixed rails.

2.3 Sway Control Becomes More Critical

With a higher lifting height, container or hook sway becomes more pronounced. This affects:

• Positioning precision

• Lifting cycle time

• Safety of adjacent workers and equipment

For this reason, tall-height RTGs often incorporate anti-sway systems, using sensors, PLC control, or differential motor drive to stabilize loads.

3. Effects on Hoisting Mechanisms and Motor Selection

3.1 Longer Hoisting Mechanism Travel

Higher lifting height requires a longer reeving system and rope length. This influences:

• Drum diameter and width

• Reeving complexity (e.g., 6/2, 8/2, or 10/2 rope systems)

• Hoisting gear design

• Braking torque requirements

More rope also means greater mass, affecting acceleration and deceleration performance.

3.2 More Powerful Motors for Tall Lifting Heights

A taller lifting height often requires:

• Higher torque motors

• Larger motor capacity to maintain lifting speed

• Stronger gearboxes

• Reinforced braking systems

Without these reinforcements, lifting speed may drop significantly due to the increased travel distance and rope load.

3.3 Lower Hoisting Speed or Higher Power?

Operators often face a choice:

• Keep the same hoisting speed with a stronger motor (higher cost), or

• Accept a slower hoisting cycle to reduce power consumption.

For container terminals demanding high throughput, the first option is more common.

4. Influence on Trolley Design and Performance

4.1 Trolley Weight vs. Height

Higher lifting systems add more structural weight, which increases:

• Trolley wheel loads

• Rail/wheel wear

• Required trolley motor power

This is especially important for RTG container cranes used outside container terminals, where the trolley may carry special hooks, slings, or lifting beams that add further weight.

4.2 Trolley Sway and Anti-Skew Control

At greater heights, the risk of trolley skewing increases. Advanced RTGs often include:

• Auto-skew correction

• Laser-based position sensors

• Real-time alignment systems

These features help maintain alignment between the trolley, the load, and the chassis.

5. Impact on Safety Systems and Load Control

5.1 Wind Resistance Requirements

Taller cranes present larger surface areas exposed to wind. Therefore:

• Higher lifting height requires stronger wind-proofing features

• Parking locks, storm brakes, and anemometers become essential

• Additional stability calculations are required for outdoor sites

5.2 Fall Protection and Emergency Stops

More height increases the need for:

• Fall arrest systems for maintenance staff

• Rope failure protection

• Backup braking systems

• Over-hoisting and over-lowering limit switches

Safety considerations expand significantly as lifting height grows.

5.3 Enhanced Visibility Solutions

When operators lift higher, visibility becomes more challenging. Many cranes integrate:

• CCTV systems on the trolley

• Laser alignments

• 3D anti-collision systems

• Remote operating stations

These ensure safe handling even when loads are lifted beyond natural line of sight.

6. Effects on Power Supply Configuration

6.1 Cable Length and Management

For cable-powered RTGs (diesel-free designs), higher lifting heights require:

• Longer power cables

• Expanded cable reel systems

• Heavier-duty drag chains

Cable management becomes more complex and maintenance costs increase accordingly.

6.2 Energy Consumption

Higher lifting height increases total lifting cycles, raising energy consumption. Solutions include:

• Regenerative drives

• Variable frequency drives (VFDs)

• Energy-saving modes

• Hybrid or fully electric RTG systems

These technologies help offset the rising energy demand.

7. Cost Implications of Higher Lifting Height

Lifting height can significantly impact the overall cost of an RTG crane. Key cost-intensive areas include:

7.1 Structural Steel

Taller frame = more steel = higher cost.
Cost increases are nonlinear because:

• Thicker plates may be required

• Reinforcements multiply as height grows

• Stress concentration demands more precise fabrication

7.2 Machinery and Electrical Components

Higher hoisting height requires:

• Larger motors

• Stronger brakes

• Bigger gearboxes

• More complex control systems

These upgrades can raise total gantry crane cost by 10–25% depending on height.

7.3 Production and Installation Costs

Manufacturing tall RTGs involves:

• Larger workshops and welding stations

• More complex assembly

• Higher transport height (may require disassembly)

Installation also becomes more challenging, especially in confined yards.

8. How to Determine the Right Lifting Height

Customers must evaluate:

• Maximum stacking requirements

• Clearance for special cargo

• Future scaling (e.g., moving from 4+1 to 5+1 stacking)

• Site restrictions

• Safety clearances and local standards

Often, selecting slightly more height than current operations require ensures long-term flexibility.

Conclusion

Lifting height requirements are one of the most influential factors in the design of a rubber tyred gantry crane. Increased lifting height affects almost every aspect of RTG design—from structural engineering and stability to motor sizing, trolley performance, safety systems, power supply configuration, and investment cost. Understanding these impacts helps terminal operators, logistics providers, steel mills, and precast concrete plants choose an RTG crane that aligns with their operational needs today while accommodating future growth. A well-designed RTG with appropriate lifting height ensures greater efficiency, safety, and lifecycle value across a wide range of industrial applications.