Container Gantry Cranes are large lifting equipment widely used in modern ports, railroad yards and large logistics centers. Operating a container gantry crane requires specialized skills and carries a high degree of safety responsibility. This article will provide you with a detailed professional guide, including standard operating procedures and key considerations for container gantry cranes, to help operators more deeply grasp the professional skills to ensure safe and efficient operations.
What is a Container Gantry Crane?
Container gantry crane is specially designed for loading, unloading, stacking, and transshipment of containers in container yards. Usually equipped with a special container spreader (such as a telescopic container spreader or a fixed container spreader), it can efficiently handle international standard containers such as 20 feet, 40 feet, 45 feet, etc., and some models can realize double container lifting operations. According to different application scenarios, they can be divided into two major types: rail-mounted container gantry cranes (RMG) and rubber tired container gantry cranes (RTG); RMG rail-mounted has the features of accurate positioning, energy saving, and environmental protection, and is widely used in modern container terminals and railroad junctions.
Rail Mounted Gantry Crane
Rubber-Tired Container Gantry Cranes
Containerized gantry crane operation before preparation
Equipment inspection
Before the operation, a comprehensive equipment status check must be carried out, as follows:
Structural components inspection: confirm that the main beam, outriggers, traveling mechanism, and other metal structures are not deformed, loose, cracked, or corroded.
Electrical system test: check whether the braking system of each control button, limit switch, and emergency stop device is normal.
Wire rope and spreader inspection: confirm that there is no broken wire, deformation, excessive wear and tear, etc., and the twist lock mechanism is flexible and reliable.
Track condition confirmation: remove debris on the track and check whether the gap of track joints meets the standard (usually 3-5mm).
Environmental assessment
Wind speed monitoring: operations should be stopped when the wind speed exceeds 15m/s (about 7 winds).
Visibility confirmation: Fog, heavy rain, and other adverse weather conditions should be assessed for suitability for operation.
Operation area clearing: there are no people and obstacles within the crane's traveling range and under the spreader.
System Startup
Turn on the power in the order specified by the manufacturer.
Carry out a no-load test run to test whether the movements of the large traveling crane, the small traveling crane operation, and the hoisting mechanism are normal.
Check whether each safety device (anti-collision system, anemometer, height limiter, etc.) is effective.
The standard operating procedures for container gantry cranes
Container lifting operation
Accurate positioning: through the cab monitoring system or ground command, the center of the container spreader is aligned with the center of the container, and the error should be controlled within ±50mm.
Lowering of spreader: Slowly lower the spreader to about 1 meter above the container and pause to confirm that the twist lock is aligned with the corner pieces of the box.
Locking confirmation: continue to lower the spreader until the twist locks are completely embedded in the corner pieces of the box, and confirm that all the twist locks (usually 4 or 8) have been reliably locked using the indicator light or meter.
Trial lifting check: lift the spreader 5-10cm, pause, observe whether the container is balanced, confirm that there is no abnormality, and then continue to lift.
Container handling
Smooth lifting: to raise the container to a safe height at an even speed (usually not lower than the highest container on the yard, 2 meters).
Horizontal movement: first, run the trolley to the target position above, and then move the trolley to avoid the compound action at the same time.
Precise positioning: switch to low-speed gear when approaching the target position, so that the placement accuracy reaches within ±25mm.
Safe Placement: Slowly lower the container and release the twist lock after confirming that the load display returns to zero when the container is fully loaded.
Special working conditions
Double-box operation: When using a special double-box spreader, make sure the total weight of the two containers does not exceed 80% of the rated load.
Dangerous goods box operation: operate strictly according to the classification of dangerous goods signs, keep smooth and no impact, and reduce the working speed if necessary.
Key Safety Precautions
Operation discipline
It is strictly prohibited to violate the rules of command, operation, and labor discipline.
It is prohibited to carry people on the lifted container or to carry out maintenance in a suspended condition.
Do not utilize the limit switch to operate the stop.
Load management
Strictly implement the rated load regulations, including:
Overloading operation is not allowed.
Pay attention to load curve changes (the larger the working range, the smaller the allowable load).
After a sudden unloading (e.g., container drop), the controller should be zeroed first.
The bias load of goods in the container shall not exceed 60% of the marked load of the box.
Emergency handling
Sudden power failure: Immediately return all the controllers to zero position, place the container safely through the backup power, or activate the manual release device.
Equipment abnormality: If there is an abnormal sound, vibration, or electrical spark, stop the operation immediately and report for maintenance.
Collision accidents: If a collision occurs, you must stop the machine to check the structural deformation and track condition, and shall not continue to use it without evaluation.
Daily Maintenance Points
Lubrication management
Following the manufacturer's requirements cycle (usually every 100-200 working hours) for each lubrication point to fill the specified type of grease.
Pay special attention to the regular lubrication of wire rope (at least once a month).
Critical Component Inspection
Check brake pad wear weekly (remaining thickness less than 50% of the original thickness must be replaced).
Measure wheel rim wear once a month (vertical wear exceeding 15% of the original thickness should be replaced).
Electrical System Maintenance
Periodically remove dust from the electrical cabinet.
Check the working condition of the cable reel unit.
Test the sensitivity of each safety limit switch.
Operator Qualification Requirements
Must obtain a special equipment operator's license (Q4 or Q8 program). Regularly attend retraining (usually every 4 years). Specialized training provided by the containerized gantry crane manufacturer needs to be completed before the operation of new models.
Conclusion
Mastering standardized container gantry crane operation skills and specifications can not only improve operational efficiency (skilled operators can reach 30-35 boxes / hour), but also an important guarantee of safe operation. Operators should continue to learn and become skilled in operating techniques, such as remote control, automated auxiliary systems, etc., to adapt to the development trend of intelligent ports.
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