Rubber Tyred Gantry (RTG) cranes are widely used in precast concrete plants, infrastructure construction yards, and bridge segment production facilities. Their combination of high lifting capacity and flexible mobility makes them ideal for handling large precast components such as beams, wall panels, bridge segments, and concrete slabs. Unlike rail-mounted gantry cranes, RTG cranes move on rubber tires and do not require fixed tracks, allowing them to operate across multiple production zones and storage areas.
One of the most important considerations when selecting an RTG crane for sale for a precast concrete yard is its lifting capacity. Precast elements vary greatly in size and weight, and the crane capacity must be carefully matched to the production requirements. This article explores the typical capacity ranges of rubber tyred gantry cranes used in precast concrete operations and explains how these capacities correspond to different types of projects and plant scales.
Understanding Capacity Requirements in Precast Concrete Handling
Precast concrete products can range from relatively small structural panels to massive bridge girders. As a result, the lifting capacity required in precast yards can vary dramatically.
Typical precast elements include:
- Wall panels
- Floor slabs
- Concrete pipes
- Beams and columns
- Bridge segments and girders
The weight of these components can range from a few tons to several hundred tons. For example, standard precast wall panels may weigh around 20–25 tons, while large bridge beams may exceed 200 tons depending on their span and design.
Because of this wide weight range, RTG cranes used in precast production are typically categorized into several capacity classes.
Small-Capacity RTG Cranes (20–50 Tons)
Small-capacity rubber tyred gantry cranes are commonly used in smaller precast plants or for handling lighter structural elements.
Typical specifications
- Capacity: 20–50 tons
- Span: 20–35 meters
- Lifting height: 6–12 meters
These 20 to 50 ton gantry cranes are ideal for moving smaller precast components between casting beds, curing areas, and storage yards. Examples of components commonly handled include:
- Precast wall panels
- Hollow-core slabs
- Small beams
- Stair units
- Utility components
Because of their moderate lifting capacity, these cranes typically feature lighter structural frames and smaller hoisting mechanisms. This results in lower power consumption and reduced equipment cost.
Small-capacity RTG cranes are particularly suitable for:
- Small to medium precast plants
- Building component manufacturing
- Modular housing projects
- Regional precast supply facilities
Their mobility allows operators to move precast elements directly from production lines to storage zones without requiring additional transport equipment.
Medium-Capacity RTG Cranes (50–120 Tons)
Medium-capacity RTG cranes represent the most widely used category in modern precast concrete plants. Many medium to large production facilities rely on cranes within this range because they provide an excellent balance between lifting power and operational flexibility.
Typical specifications
- Capacity: 50–120 tons
- Span: 25–45 meters
- Lifting height: 10–18 meters
These cranes can handle much larger structural elements, including:
- Long-span beams
- Heavy wall panels
- Precast columns
- Large slab sections
In typical precast yards, these cranes perform several critical functions:
- Transporting finished components from casting beds
- Stacking precast elements in storage yards
- Loading components onto trucks for transportation
- Repositioning heavy elements during assembly operations
Medium-capacity RTG cranes are particularly common in plants producing precast components for:
- High-rise buildings
- Commercial developments
- Infrastructure projects
Because they can handle most precast components used in building construction, they are often considered the “standard” capacity range for precast concrete operations.
Heavy-Duty RTG Cranes (120–300+ Tons)
Heavy-duty rubber tyred gantry cranes are used in large-scale precast operations, particularly in infrastructure and bridge construction projects.
Typical specifications
- Capacity: 120–300+ tons
- Span: 35–60 meters or more
- Lifting height: 15–25 meters
These cranes are designed to handle extremely heavy components such as:
- Prestressed concrete bridge girders
- Box girders
- Large tunnel segments
- Heavy industrial precast modules
The structure of heavy-duty RTG cranes is significantly reinforced to support high loads. They often feature:
- Double girder designs
- Multiple hoisting mechanisms
- High-capacity electric or hydraulic hoists
- Advanced load monitoring systems
In some specialized infrastructure projects, RTG cranes can reach capacities far beyond the typical industrial range. Certain custom-designed systems can handle loads up to 2,000 tons for bridge construction and other mega infrastructure projects.
Ultra-Heavy RTG Systems for Infrastructure Projects
In large-scale transportation projects such as railway bridge construction, precast elements can weigh hundreds of tons. To handle these massive components, specialized RTG systems are sometimes deployed.
Typical applications include:
- High-speed railway bridge girders
- Long-span highway beams
- Large precast tunnel segments
- Offshore infrastructure components
These cranes may feature:
- Four-point lifting systems
- Multiple synchronized hoists
- Hydraulic lifting technology
- Automated load balancing systems
Ultra-heavy RTG cranes are usually custom-designed for specific projects and are rarely used in standard precast plants.
Single Hoist vs Multi-Hoist Configurations
Capacity selection in RTG cranes is not determined solely by the crane’s rated load. The lifting configuration also plays an important role.
Single-hoist RTG cranes
Single-hoist systems are typically used for:
- Wall panels
- Slabs
- Smaller precast components
They are simpler in design and easier to maintain.
Multi-hoist RTG cranes
Large precast elements often require multiple lifting points to prevent bending or structural damage. Multi-hoist RTG cranes allow synchronized lifting of long components such as bridge girders or precast beams.
These systems improve:
- Load balance
- Structural safety
- Handling precision
Factors That Influence Capacity Selection
Selecting the correct RTG crane capacity for a precast concrete facility requires consideration of several key factors.
1. Maximum Component Weight
The most important factor is the weight of the heaviest precast element produced in the plant.
Engineers typically add a safety margin when selecting crane capacity to ensure safe lifting operations.
2. Production Volume
High-volume plants often require larger cranes to handle frequent heavy lifts and maximize operational efficiency.
3. Yard Layout
The span and lifting height required depend on the layout of the precast yard, including:
- Storage stacking height
- Transport routes
- Casting bed arrangements
4. Future Expansion
Many plants choose slightly larger crane capacities to accommodate future production expansion or new product types.
Why RTG Cranes Are Ideal for Precast Plants
Rubber tyred gantry cranes are particularly well suited for precast concrete handling due to several advantages.
Mobility
Because they run on rubber tires, RTG cranes can travel freely across the yard without rail infrastructure. This allows them to serve multiple work areas and adapt to changing production layouts.
Large Working Area
RTG cranes can span large production zones, allowing them to transport components from casting beds to storage areas efficiently.
High Lifting Capacity
Modern RTG cranes typically support lifting capacities ranging from 30 tons to over 200 tons depending on design and configuration.
Flexible Operation
RTG cranes can be equipped with remote control systems, operator cabins, or automated control systems to improve efficiency and safety.
Conclusion
Rubber tyred gantry cranes play a vital role in precast concrete production by providing flexible, high-capacity lifting solutions for handling heavy structural components. Their typical lifting capacities can be grouped into three major categories:
- 20–50 tons: suitable for small precast plants and lighter components
- 50–120 tons: the most common range for standard precast production
- 120–300+ tons: used in large-scale infrastructure and bridge projects
In specialized cases, RTG cranes can be engineered to handle loads of several hundred tons or even more for mega infrastructure construction.
Choosing the right capacity requires careful consideration of component weight, plant layout, and long-term production needs. When properly selected, RTG cranes significantly improve the efficiency, safety, and productivity of precast concrete operations.
For modern precast facilities aiming to streamline heavy material handling, rubber tyred gantry cranes remain one of the most versatile and powerful lifting solutions available today.
