There’s no getting around it: cargo that doesn’t fit in a container costs more to ship than cargo that does. Transporting out of gauge cargo globally is also a more complicated process than shipping a steel box. But if you do things right, you can control the cost of shipping oversized cargo and avoid some significant headaches. This article gives you the comprehensive understanding you need to ship OOG freight smarter, safer, and for less.
What’s Different About Out of Gauge Cargo?
We call cargo oversized, or out of gauge, when it’s too tall, long, or wide to fit in a closed shipping container. Think big construction machines, extremely large panes of glass, bridge beams, and propellers for wind turbines.
Several kinds of containers are used to ship oversized cargo on the ocean. See our article on choosing the best box for your ocean cargo. The most common are:
An open top container is exactly that — instead of a solid roof, the top is open and can be covered with a soft covering. It is meant to carry oversized loads that can’t be loaded from side doors or in a regular container. It must be loaded from overhead using a crane. Some open top containers, called hard top containers, have removable steel roofs.
Downside: open top containers won’t accommodate wide loads.
The flat rack container has collapsible walls at the front and back but is open on the sides and top. Although it costs more than a standard container, it’s the right choice for an extra-wide load. It’s also one possible choice for a load that’s too long or tall for a standard container.
Since this container is open on top and at the sides, you’ll need protection against the elements — tarps, shrink wrap, or crates around the cargo. Check out our article on choosing between flat rack or RoRo.
Companies choose platform cargo boxes by process of elimination. Made from a steel frame and wooden floor, they are used for cargo that can’t be transported via other container options. The structure has an extremely high loading capacity and provides a strong base for extremely heavy and bulky cargo, like machinery.
Why Does Oversized Cargo Cost More?
When you use a specialized container for shipping out of gauge cargo, the shipping line typically adds $250 or $500 to your bill — and that’s just for the container, not the load itself. You’ll pay even more if your oversized cargo takes up more than one slot on a container vessel. If a load sticks out two feet on either side of a flat rack, the shipping line can’t fit a container immediately to the left or right. If the load extends several feet above the walls of an open container, the line can’t stack another box on top.
At least, that’s what they tell you. Most oversized cargo actually travels in the top layer of containers, where stacking isn’t an issue, or else it travels under deck. Oversized freight might not take up any extra slots at all — but the line will still charge a premium. See our breakdown of why OOG shipping costs more.
Many marine terminals charge higher handling fees for oversize containers than for conventional boxes, usually buried in the shipping line’s total rate. You’ll also pay more to transport this cargo over the road. In the U.S., loads that exceed standard height or weight restrictions need special permits, which come with fees and conditions. Depending on dimensions, you might need a route survey before a state issues the permits — and possibly an escort vehicle. Requirements vary from state to state. See our article on permit requirements for OOG cargo.
When you use a flat rack or open top container from the port to final destination, you also need to return that container to the port — so you pay the trucking company for a round trip, even though it’s carrying your cargo only one way. If the drayage isn’t far, this won’t cost much. But for long hauls, you might consider transloading the cargo onto a specialized chassis and leaving the container at the port.
Best Practices for Shipping Oversized Loads
With all the built-in extra costs of out of gauge cargo shipping, you need to look for ways to keep total costs under control. We’ve spent nearly 40 years doing just that. Here are a few tips from our article on best practices for shipping machinery and OOG cargo.
Make the load smaller
If you can reconfigure your freight so it fits in a container, that’s the best solution. We once discovered that detaching axles and wheels before loading fit a wide machine into a standard container — avoiding flat rack costs entirely. Disassembly/reassembly on either end can save 50%+ on ocean transportation even after labour costs.
Give your logistics partner accurate information
If you tell your 3PL the load is 120″ tall and 110″ wide, but the trucker finds it’s actually 128″ tall and 120″ wide, permits have to be redone — delaying delivery and costing money. This happens more often than you’d think.
Leave the conveyance at the port
Unless the final destination is close to the port, arrange to transfer your cargo from its open top container, flat rack, or platform to a truck chassis. Otherwise, the trucker will charge you for returning the empty conveyance to the port.
Secure and protect heavy machinery
If machinery doesn’t fully fill the container, the load might shift and suffer damage in transit. Use lumber to fill empty space, plus straps and chains. On a flat rack, your load must pass a National Cargo Bureau (NCB) inspection at the port — fail, and you pay to rework it before the ship will load it.
Choose a trucker that specialises in OOG cargo
Most trucking companies don’t transport oversize cargo. Others might claim they can but lack the equipment, permit knowledge, or route survey experience to do it safely, legally, and cost-efficiently. A trucker without solid OOG experience could cause cargo damage, transportation delays, or highway accidents.
Ensure proper weight distribution
The Bridge Gross Weight Formula requires that heavier loads use longer chassis with more axles, distributing weight so it doesn’t damage highways. Even if a trucker’s permit shows the right dimensions and weight, if the weight isn’t distributed correctly over axles, an inspector will pull the truck off the road.
Buy from a location that makes sense
If your seller is near an East Coast port and you’re shipping to Europe, transportation costs are manageable. But if the seller is in Kansas, the overland leg gets complicated and costly. When shipping large construction machinery, figure out port transportation costs before making the purchase.
Keep it clean
A few streaks of mud on earthmoving equipment undercarriage can get your shipment turned away at the destination port. Customs inspectors follow regulations to prevent invasive species from hitching a ride. Before shipping overseas, arrange a pressure wash to remove all traces of soil and debris.
Case Study: OOG Shipping Without the Pain
Sometimes the best solution for transporting out of gauge cargo is to contact an expert. Here’s how one Polish manufacturer got it right (read the full case study).
The Challenge
A manufacturer in Poland bought a huge CNC machine from a company in Maine, USA — valued at approximately $105,000. Once crated, the oversized cargo was about the size of a large excavator. The buyer needed to get it out of the factory in Maine, pack it safely, book it on a ship, get it to a Polish port, clear customs, and deliver it to their facility. No one at the Polish company knew how to manage such a complex move.
How I.C.E. Managed It
- I.C.E.’s U.S. office hired a rigging company in Maine to remove the machinery from the factory using portable cranes and forklifts, loading it onto a truck for transport to a warehouse.
- A custom crate was built with no wasted space, using heat-treated lumber to guard against invasive insects.
- OOG permits were obtained for transport to I.C.E.’s warehouse in Edison, NJ, using a specialist OOG trucker.
- A 40′ flat rack container was brought to the Port of NY/NJ; an overhead crane loaded the crate, which was then blocked, braced, and lashed to NCB standards.
- The container passed port inspection and made an uneventful ocean crossing.
- In Poland, I.C.E. Transport’s customs office in Gdynia cleared the load and arranged final delivery to the buyer’s facility.
A truck hauling flat rack machinery crossed a state line and the driver’s permit said the load was 112″ wide. The inspector found it was actually 117″. Those five inches took the truck off the road on a Friday afternoon. The load sat until Monday while a new permit was arranged — causing the cargo to miss its sailing date. The shipper paid for two trucks, port rebooking, and rescheduled permits in the destination country. Moral: get the dimensions right during the planning stage.
Mistakes to Avoid When Shipping Out of Gauge Cargo
Here are five common OOG cargo shipping mistakes we’ve seen in our many years managing such moves.
Providing the wrong dimensions and weight
Truckers who can handle project cargo are few and picky. One who agrees to a 129′ load might back out when the actual length is 131′. If the permits don’t match reality at pick-up, the trucker has to refile — delaying the shipment and costing money.
Forgetting technical drawings or handling instructions
Crane crews can’t guess where to connect their equipment. You must provide technical drawings with lift points and centre of gravity clearly marked, plus handling instructions — otherwise your load might tip, causing a dangerous and expensive accident.
Skimping on insurance coverage
Marine cargo insurance costs far less than replacing damaged cargo. If a load worth $500,000 is damaged in transit, the carrier may pay only $500. The more your load is worth, the smarter it is to purchase your own marine cargo insurance.
Vague instructions about necessary equipment
When a trucker arrives to pick up or drop off project cargo, you typically get one or two hours before overtime charges kick in — at $400–$500 per hour, versus $100 for standard containers. Be very clear with everyone about the need to stay on schedule.
Automatically choosing the cheapest route
Freight rates are like air fares: more stopovers usually means lower cost. But every time you transfer project cargo from ship to ship or ship to truck, you increase the risk of damage. Consult your logistics partner to strike the right balance between cost and risk.
The Advantages of an Experienced Freight Forwarder
Project cargo freight forwarders provide outsized advantages when you’re shipping out of gauge cargo overseas. If you’re not part of a large organization that ships this kind of equipment regularly, you probably don’t have staff who know how to:
- Secure and protect the load correctly to NCB standards
- Find truckers that specialize in overweight and/or oversize loads
- Classify the machinery correctly to clear customs on both ends
- Arrange transportation in another country, especially without speaking the local language
When you ship oversized project cargo, there’s a lot at stake and plenty that can go wrong without experience. Forwarders with OOG shipping expertise minimize your risk — taking charge of your equipment from origin to final delivery, figuring out the best shipping method, securing qualified transportation partners, handling permitting and documentation, and tracking progress through every step.
Need help with OOG cargo shipments?
Contact one of I.C.E. Transport’s out of gauge shipping specialists. We’ve been managing complex oversized moves since 1987 — between the U.S. and Poland, Eastern Europe, and beyond.