How Long Does It Take to Install a Rubber Tyred Gantry Crane?

Rubber Tyred Gantry (RTG) cranes have become an essential piece of equipment in modern ports, container yards, and industrial warehouses due to their mobility, flexibility, and ability to handle heavy loads efficiently. However, installing an RTG crane is a complex task that requires careful planning, engineering, and coordination among multiple teams. Many operators and facility managers often ask: “How long does it take to install a rubber tyred gantry crane?” The answer is not straightforward because the installation timeline depends on several factors, including crane type, site conditions, required foundation work, and additional customization. In this article, we’ll explore the full scope of the installation process, the factors that influence the timeline, and best practices to ensure a smooth installation.

Understanding Rubber Tyred Gantry Cranes

Before diving into installation timelines, it’s important to understand the nature of RTG cranes. Unlike rail-mounted gantry cranes, RTGs move on rubber tires, making them highly mobile across container yards and industrial sites without needing fixed tracks. This mobility provides flexibility for operations, but it also introduces unique installation considerations. A rubber tyred gantry crane for sale is typically a large, heavy-duty machine with spans ranging from 18 to 45 meters and lifting capacities from 40 to over 100 tons. Due to their size and complexity, proper installation is critical to ensure safety, operational efficiency, and longevity of the equipment.

Key Steps in Installing an RTG Crane

Installing an RTG crane is more than just assembling the crane at the site. It involves a structured sequence of steps, each contributing to the overall timeline:

1. Site Preparation

Site preparation is one of the most crucial phases and can significantly impact the installation timeline. The area must be leveled and cleared of obstacles, with adequate access for transportation of heavy components. For RTG cranes, which often weigh several hundred tons, ensuring the ground can support the crane’s weight without sinking or shifting is essential. If the site lacks a suitable pavement, reinforced concrete or asphalt pads may need to be installed, which can take several weeks depending on local conditions and weather.

2. Foundation and Pavement Work

Even though RTGs do not run on rails, they require strong ground support. The pavement must be designed to handle concentrated loads from crane wheels, and in some cases, special foundation pads are required to prevent uneven settlement. Preparing and curing concrete pads can add anywhere from two to four weeks to the project timeline.

3. Transportation and Logistics

RTG cranes are typically shipped in parts due to their massive size. Components such as the crane bridge, lifting trolley, spreader, and wheel assemblies must be transported to the site, often requiring heavy-duty trucks, cranes, and careful coordination with local authorities for oversized loads. Transport logistics can add several days to a few weeks depending on the distance, customs clearance (for imported cranes), and local road regulations.

4. Assembly of Crane Structure

Once all components arrive at the site, assembly can begin. The bridge girder, gantry legs, trolley systems, and hoist mechanisms are lifted into place using auxiliary cranes. For a standard 40–60 ton RTG crane, assembly can take approximately 7 to 10 days if all components are on-site and skilled technicians are available. Larger cranes or customized configurations may take up to 2–3 weeks.

5. Mechanical and Electrical Installation

After the physical structure is assembled, mechanical and electrical systems need to be installed and tested. This includes the installation of:

• Hoist motors and brakes

• Trolley drive systems

• Crane control systems (often PLC-based)

• Hydraulic or pneumatic components (if applicable)

• Lighting and safety devices

Electrical wiring, connection to power supplies, and testing of motors can take an additional 5–7 days. For cranes with sophisticated automation features or anti-sway systems, this phase may extend further.

6. Calibration and Testing

Before an RTG crane can be put into operation, precise calibration is required. This includes:

• Aligning wheels for smooth movement

• Testing lifting mechanisms under no-load and full-load conditions

• Checking limit switches, safety interlocks, and control systems

• Verifying load distribution and structural stability

Load testing can take 1–3 days depending on the complexity of the crane and the weight of the test load. Some facilities require third-party inspectors to certify the crane’s performance, which can add a few more days.

7. Training and Handover

After installation and testing, operators must be trained to safely and efficiently operate the RTG crane. Training sessions usually take 1–2 days and include hands-on operation, emergency procedures, and routine maintenance checks. The final handover marks the official operational readiness of the crane.

Factors Affecting Installation Duration

Several factors influence how long it takes to install an RTG crane:

1. Crane Size and Complexity

Larger cranes with higher lifting capacities or longer spans require more time for assembly, alignment, and testing. Cranes with additional features like automated stacking, remote control, or anti-sway mechanisms may extend installation timelines.

2. Site Conditions

The quality and preparedness of the site are critical. Uneven ground, poor drainage, or inadequate pavement can lead to delays as foundation work and ground leveling are completed. Environmental factors such as extreme temperatures, heavy rain, or high winds can also delay installation.

3. Availability of Skilled Labor

Installing an RTG crane requires skilled technicians, electricians, and engineers. Delays often occur if trained personnel are unavailable, especially in remote locations or regions with labor shortages.

4. Logistics and Transportation Challenges

Transporting large crane components to the site can be a logistical challenge. Delays in customs clearance, road permits, or transportation accidents can significantly extend the project timeline.

5. Customization and Optional Features

Some RTG cranes are customized to meet specific operational requirements. Optional features such as hydraulic steering, extended boom lengths, or advanced control systems can add complexity and increase installation time.

Typical Timeline

Based on industry experience, a standard RTG crane installation typically takes 4 to 6 weeks under optimal conditions. This includes site preparation, foundation work, assembly, electrical and mechanical installation, testing, and training. Larger or heavily custom gantry cranes can take up to 8 weeks or more.

Phase	Estimated Time
Site Preparation	1–2 weeks
Foundation / Pavement Work	2–4 weeks
Component Transportation	1–2 weeks
Crane Assembly	1–3 weeks
Mechanical & Electrical Setup	5–7 days
Calibration & Load Testing	1–3 days
Operator Training & Handover	1–2 days

Best Practices to Reduce Installation Time

To minimize installation time without compromising safety and quality, consider the following:

1. Early Planning: Conduct site surveys, engineering assessments, and logistics planning well in advance.

2. Pre-assembly: Where possible, assemble sections of the crane offsite to reduce on-site installation time.

3. Skilled Teams: Hire experienced RTG installation specialists to streamline assembly and calibration.

4. Weather Contingency Plans: Schedule installation during favorable weather periods and prepare for delays caused by adverse conditions.

5. Clear Communication: Maintain coordination between crane suppliers, transport teams, site engineers, and operators to avoid unnecessary delays.

Conclusion

The installation of a rubber tyred gantry crane is a multi-stage process that requires careful planning, technical expertise, and coordination among multiple teams. While the exact duration depends on factors such as crane size, site conditions, transportation logistics, and customization, most installations can be completed within 4–6 weeks. For large or highly customized cranes, the process may extend to 8 weeks or longer. By following best practices in site preparation, assembly, testing, and operator training, facility managers can ensure that their RTG cranes are installed efficiently, safely, and ready to optimize material handling operations.

Proper planning and execution not only reduce installation time but also enhance the operational efficiency and lifespan of the crane, making it a worthwhile investment for any container yard or industrial site.