Standardised intermodal shipping containers revolutionised global transport and logistics thanks to their stackable, road/rail-transportable design. However, efficiently loading, unloading, and handling these heavy metal boxes at ports, storage depots and distribution hubs requires specialised forklifts with capabilities exceeding those of traditional models.
So, which forklift types can safely lift, manoeuvre and stack bulky 20-40 tonne containers?
Challenges of Container Forklift Operations
Handling shipping containers poses unique difficulties compared to regular pallet transport:
- Massive weight – 20-45 tonne containers demand enormous lifting capacities from forklifts. Forklifts must also counterbalance the protruding front load.
- Sheer container size – Spanning up to 12 metres long, containers restrict manoeuvring in tight port spaces.
- Stack handling – Container handlers must carefully lift containers from storage stacks 4-5 units high without destabilising other containers.
- Dynamic steel construction – Unlike wooden pallets, smooth, distorted container sides reduce forklift traction. Forks can also easily damage containers if not cautious.
- Outdoor operation – Container forklifts work outdoors year-round in port environments exposed to moisture, dirt and debris.
These challenges make container handling unsuitable for standard counterbalance forklift models. Instead, purpose-built container movers are necessary.
Key Types of Container Forklifts
Container forklifts typically utilise heavy counterweight designs for lifting containers via one of these arrangements:
Top handlers
Top handlers lift containers from above using a pair of lifting beams inserted into the corner castings on the top of the container. This top-down lifting provides optimal stability when stacking containers and avoids collisions. However, top handlers lack the reach to load ground-level containers into confined vessel cargo holds.
Reach Stackers
Reach stackers lift containers from ground level using an extendable telescoping boom that reaches out to grab containers. This longer reach makes it easier to load and unload storage stacks and lorry trailers, but it has less visibility than top handlers.
Forked Container Lift Trucks
These rugged forklifts slide their lifting forks directly through the container’s front end frame to raise it off the ground for relocation. The fork design provides simplicity but reduces visibility, plus sudden braking risks penetrating and damaging the container front.
Container Handling Attachments
Forklift attachments can upgrade standard forklifts if dedicated container movers are unavailable. For example, a forklift fitted with a large curved container handling bracket can reposition the container in a limited capacity.
Key Specifications for Container Forklifts
Alongside different lifting methods, ideal container handlers also possess:
- Heavy lift capacity – Up to 45 tonnes or higher to hoist maximum container weights.
- Telescoping masts – Allows high stacking and multi-level warehouse storage access.
- Durable carriages – Reinforced steel masts and frames withstand repetitive maximum load cycles.
- Advanced hydraulics – Smooth precision control when lifting and positioning containers.
- All-wheel drive – Excellent traction, acceleration and braking in outdoor port environments.
- Impact protection – Padding shields from protruding container edges during handling.
- Spacious protected cabs – Allows continuous operation in poor weather prevalent at port sites.
- Swivelling cabs – Enables optimal visibility when travelling or stacking in either direction.
- Automatic deceleration – Prevents knocking over the container stack when placing boxes.
Acquiring the correct container specifications substantially improves long-term reliability and productivity on intensive handling jobs.
Other Considerations for Container Forklifts
Along with sturdy lift designs and heavy-duty components, container handlers benefit from:
- Operator ergonomics – Comfortable seats, controls and optionally enclosed climate-controlled cabs allow extended operation for 10-12 hour port shifts.
- Reliable support – Container operations run 24/7, so expert after-hours service and preventative forklift maintenance are essential to maximise uptime.
- Forklift training – Experienced operators understand optimal gripping points, smooth driving techniques and hazard avoidance for fragile loads and congested yards.
- Financial options – Outright purchases, long-term leasing and short-term rentals all provide different advantages when acquiring container fleets.
With heavy containers costing thousands per day in detention fees when delayed, properly equipped container-handling forklifts in the hands of skilled drivers are a wise investment for ports and shipping companies.
Trust TAG Forklift Trucks as Your Materials Handling Partner
At TAG Forklift Trucks, we have over 20 years of experience providing the right materials handling equipment to get any job done efficiently and safely. Whether you operate a major shipping hub or a smaller distribution warehouse, we can advise you on the ideal forklift solutions tailored to your cargo volumes, space constraints, budgets, and growth plans.
Besides forklift sales and rentals, we also handle operator training, safety auditing, maintenance and more. Contact TAG Forklift Trucks today at 0161 848 0555 to discuss optimising your container logistics productivity.