What is Heavy Haulage? Equipment, costs, regulations, and process explained

Looking to transport extremely large and heavy cargo? Think blades for wind turbines, huge construction machinery (like long beams), or even bulky army tanks.

We’re talking about heavy haulage.

It involves a complex process with specialised equipment, strict regulations, and meticulous planning. Keep reading to learn about the key aspects of this type of logistics.

Overview of heavy haulage logistics

What is heavy haulage?

Heavy haulage is the transportation of oversized and overweight cargo that can't be safely carried by standard containers or trucks. These loads exceed the standard legal limits for size, weight, height, and width — requiring specialised equipment, vehicles, and permits to be transported.

Since it’s primarily moved by trucks and trailers, it is also called heavy haul trucking.

What qualifies as a heavy haul?

The specific freight parameters vary by region due to differing regulations and road infrastructure capabilities. Different logistics providers will also have different specifications.

What equipment and vehicles are used for transporting heavy haul?

• Heavy haul trucks: These aren’t your average pickups! They’re built with multiple axles and powerful engines to handle the immense weight. Some even have modular configurations that can be extended for super-long loads.
• Trailers: There are various trailers to fit different cargo. Lowboy trailers provide extra ground clearance for tall objects, while extendable trailers can accommodate exceptionally long pieces of freight.
• Lifting and positioning equipment: Depending on the cargo, cranes, dollies, and other special equipment might be needed for safe loading and unloading.

READ MORE: What is road haulage?

Which industries use heavy haul logistics?

These industries rely on heavy haul logistics to move the equipment they need to function:

• Construction: Cranes, bulldozers, excavators, and prefabricated building components.
• Energy: Turbines, generators, transformers, and reactors for power plants, oil and gas refineries, and wind farms.
• Manufacturing: Large machinery and equipment used in production lines.
• Oil and Gas: Drilling rigs, pipes, and other items used in exploration and production.
• Wind Energy: Wind turbine blades, towers, and nacelles to wind farms.
• Aerospace: Large aircraft components, such as wings and fuselages.

At Maersk, we offer integrated solutions to handle your unique transportation and supply chain needs for all types of cargo across industries. Explore Maersk Project Logistics.

How is heavy haulage different from project logistics?

Imagine building a house… Heavy haulage would be the process of delivering the giant crane needed for construction. Project logistics would be the entire plan for getting all the building materials (from lumber to roofing tiles) to the site — on time and in the right order.

Both are interconnected but have different roles within the big picture of moving massive or complex cargo. Here’s how they differ:

Heavy haulage: The muscle

Focus: Concentrates on the movement itself of oversized or overweight cargo.

Expertise: Involves heavy-duty equipment like specialised trailers, cranes for lifting, permits for oversized loads, and planning safe routes that accommodate the massive cargo.

Part of the Picture: Crucial but specific step within the larger project logistics process.

Project logistics: The mastermind

Focus: Takes a holistic approach to managing the entire transportation process for large, complex projects.

Scope: Goes beyond just the heavy haul. This includes planning, coordinating, and overseeing all aspects of moving equipment and materials (from origin to final destination).

Tasks Involved: Selecting the most efficient transportation modes (ship, truck, rail) or a combination; Coordinating with ports, customs clearance, and inland transportation; Ensuring proper packing, securing, and lashing of cargo for safe travel; Obtaining necessary permits and managing risks; Scheduling deliveries to meet project timelines.

Need help with project logistics? Take a look at Maersk Project Logistics services.

Moving the haul: The process of heavy haul transportation

1. Planning and permits: The process starts with obtaining the necessary licences based on the most suitable equipment and travel route for the cargo.
2. Route planning: A detailed route is planned considering weight restrictions, clearances, and potential obstacles like traffic.
3. Loading and securing: The cargo is carefully loaded onto the trailer using specialised lifting equipment and securely fastened with heavy-duty tie-downs to prevent any shifting during transport.
4. Transportation: The heavy haul vehicle, often accompanied by pilot cars and escorts, proceeds along the designated route with careful attention to safety and traffic flow.
5. Unloading and delivery: Once at the destination, the cargo is safely offloaded using cranes or appropriate equipment.

Costs involved in heavy haul trucking

The cost of heavy haulage varies depending on several factors like size and weight of the load, transportation distance, route complexity, peak season, and local regulations. However, there are some fixed costs for transporting heavy haul, including those for:

• Permits: Oversized/overweight loads require permits to travel on public roads. These costs vary depending on the size and weight of the cargo, as well as the travel distance.
• Fuel: The sheer size and weight of heavy haul vehicles translate to higher fuel consumption, impacting the overall cost.
• Pilot/escort cars: Large loads require pilot cars to lead the way and escort vehicles following behind to ensure safety and manage traffic flow, which adds to the costs.
• Specialised labour: Heavy haulage jobs require experienced personnel with specialised training and certifications to operate the equipment and handle the logistics.

Regulatory considerations in heavy haulage

When transporting oversized or heavy haulage loads, awareness and comprehension of legal and regulatory requirements are vital — to ensure safety on the road during transportation. Both federal and state regulations come into play, varying significantly across different regions.

• Weight and size limits: Every region has regulations on the maximum weight and dimensions a vehicle can legally carry on public roads. Exceeding these limits necessitates permits and potential route restrictions.
• Route planning: Heavy haul licences specify the route the vehicle can take. This considers factors like bridge clearances, road capacity, and potential traffic disruptions.
• Safety regulations: Heavy haulage equipment and operations are subject to strict safety regulations. These cover everything from vehicle maintenance to load securement and pilot car protocols.

Additional considerations and tips for heavy haulage

Tips for pre-haul planning

• Weather conditions: Be aware of weather forecasts. High winds, rain, or snow can impact safety and may necessitate route adjustments or postponing the haul.
• Nighttime transport: Night travel can sometimes be easier due to less traffic. However, ensure proper lighting and signage on the vehicle for increased visibility.
• Public awareness: For very large or disruptive loads, consider notifying local authorities and residents along the route in advance to minimise surprises and delays.

Safety measures to transport heavy haul

• Pre-trip inspections: Before each haul, check the truck, trailer, and all lifting and securement equipment to ensure everything is in proper working order.
• Load securement: Triple-check that the cargo is securely fastened using appropriate straps, chains, and blocking mechanisms to prevent any shifts during transport.
• Driver training: Ensure drivers are highly trained and experienced in handling heavy haul vehicles and manoeuvring oversized cargo.
• Route familiarisation: If possible, for highly complex routes, have a pilot car driver familiar with the road beforehand to make transportation smoother and more efficient.

Communication and coordination tips

• Teamwork: Ensure clear communication and well-defined roles for everyone involved, from the driver and pilot car crew to the loading and unloading personnel.
• Contingency plans: Have a plan B in case of unexpected obstacles or delays on the route. This might involve alternate routes or securing additional permits if needed.
• Invest in technology: Utilise GPS tracking systems and route planning software to optimise efficiency and ensure adherence to permitted routes.

And of course, work with a reliable and experienced logistics service provider (like Maersk!) to move your heavy haul. Explore our end-to-end special transport services.