Before diving into customization, it’s important to understand the common container sizes in global logistics. The International Organization for Standardization (ISO) has defined the most common types:

20-foot container (TEU): 6.06m x 2.44m x 2.59m

40-foot container (FEU): 12.2m x 2.44m x 2.59m

40-foot High Cube container: 12.2m x 2.44m x 2.90m

45-foot High Cube container: 13.7m x 2.44m x 2.90m

Special containers such as refrigerated containers, tank containers, and flat racks may have different dimensions and handling needs.

Customizing rail mounted gantry cranes to handle these variations ensures operational efficiency, minimizes damage risk, and maximizes throughput.

Why Customization Matters

1. Improved Efficiency

Each container size requires different lifting positions and spreader configurations. A well-customized RMG crane can quickly adapt to size changes without time-consuming manual adjustments.

2. Enhanced Safety

Customizations such as automated size detection and container locking mechanisms reduce human error, minimizing accidents and cargo damage.

3. Adaptability for Mixed Handling

In yards where multiple container types are handled daily, flexibility in crane operation becomes a strategic advantage.

4. Cost Optimization

Efficient handling leads to faster turnaround times and less idle time for equipment, which translates to lower operational costs.

Key Customization Parameters

1. Spreader Design and Adjustment Mechanism

The spreader is the most crucial component in container size handling. Customization includes:

Telescopic Spreaders: These can extend or retract to accommodate 20ft, 40ft, and 45ft containers.

Automatic Position Adjustment: Motorized systems adjust the spreader length and lock positions automatically based on container type.

Twin-Lift Capability: For terminals requiring high throughput, twin-lift spreaders can lift two 20ft containers simultaneously.

2. Crane Span and Rail Gauge

While the rail gauge is typically fixed according to the yard design, the crane span must accommodate stacking containers across multiple tracks and lanes. The customization may include:

Wider spans for multiple rail lines or truck lanes

Higher stacking heights to accommodate container stacks of different sizes and weights

3. Hoisting and Trolley Systems

Lifting mechanisms must support the weight of the largest containers, including fully loaded 45ft high cubes. This requires:

Adequate lifting capacity (typically ranging from 30 to 50 tons or more)

Fast hoisting speeds with variable frequency drives (VFDs)

Anti-sway systems to maintain precise container placement

4. Automation and Smart Control

Intelligent systems enhance crane versatility and minimize downtime:

Container recognition systems using RFID or vision technology

Yard management system integration to automatically select the correct spreader size

Automated positioning and alignment for faster cycle times

Step-by-Step Customization Process Step

1: Identify Container Mix and Yard Layout

Start by evaluating the container types most frequently handled. Will your terminal primarily deal with 20ft and 40ft containers, or are 45ft and specialty containers common? Also assess:

Rail lane configurations

Truck lanes and loading points

Stacking heights and density requirements

Step 2: Define Crane Specifications

Based on the above data, define:

Lifting capacity (e.g., 40–50 tons)

Span and lifting height (e.g., 32m span, 12m lifting height)

Required work duty (e.g., A5–A8 based on operating hours)

Hoisting speed and trolley travel speed

Step 3: Select or Design the Spreader

Customize or select a telescopic spreader suitable for the anticipated range of container sizes. Consider:

Twistlock system type

Extension and retraction speed

Rotation and alignment mechanisms

Step 4: Integrate Control and Detection Systems

Include intelligent systems for:

Container size detection

Automatic spreader adjustment

Collision avoidance

Remote diagnostics and performance monitoring

Step 5: Adapt Mechanical Structure

Ensure the crane structure - including girder design, trolley rail placement, and spreader carrier - accommodates the necessary movements for handling varying container lengths.

Step 6: Test and Commission

During factory acceptance testing and on-site commissioning:

Simulate container handling scenarios with different sizes

Calibrate sensors, software, and controls

Train operators on mixed-load operations

Case Example: RMG Crane for Mixed Container Handling

A logistics operator in Central Asia needed a solution for a container yard adjacent to a railway terminal. They required an RMG container gantry crane that could handle:

20ft, 40ft, and 45ft containers

Daily handling of over 100 containers

Harsh weather conditions with wind and snow

Solution Highlights:

Customized RMG crane with a 32m span and 12.5m lifting height

Telescopic twin-lift spreader with automatic locking

Work duty A6 for intensive operations

Integrated yard management system

Anti-sway system and automatic container positioning

This customization allowed for fast switching between container sizes, reduced human error, and significantly improved throughput.

Tips for Choosing the Right RMG Customization Partner

Experience Matters: Choose a supplier with proven experience in container crane customization.

Turnkey Solutions: Opt for manufacturers that offer design, fabrication, testing, delivery, and installation services.

After-Sales Support: Look for providers offering spare parts, maintenance, and operator training.

Digital Integration: Ensure compatibility with your terminal’s software and digital infrastructure.

Conclusion

Customizing RMG cranes for specific container sizes is no longer a luxury but a necessity for modern logistics hubs. Whether handling standard ISO containers or accommodating a variety of containerized cargo, the right customizations - from spreader design to smart automation - ensure operational excellence, safety, and long-term cost savings.

At Aicrane, we specialize in tailor-made RMG crane solutions for rail terminals, ports, and logistics facilities. From detailed consultations to final installation, our engineering team ensures your crane is perfectly adapted to your handling needs - now and in the future.