Project cargo is a broad term for shipments that need more planning than a standard container: goods too big, too heavy or too awkward to load in a dry box, or a set of shipments that has to arrive together for a project. It might be a single machine for a factory in the Midlands, or several loads of plant equipment for an overseas site. Either way, the work is mostly in the planning.
What counts as project cargo?
- Out-of-gauge (OOG) cargo: too wide, too tall or too long for a standard container, such as machinery, tanks, transformers and boats
- Heavy lift cargo: individual pieces too heavy for normal handling or road limits
- Breakbulk: large items loaded straight onto the ship rather than in a container, such as steel beams, pipes and very large machinery
- Ro-ro cargo: wheeled or tracked items driven on and off the ship, including vehicles, plant and items moved on roll trailers
- Multi-shipment projects: equipment for a plant or site that must arrive in the right order and on time
Choosing the right equipment
| Option | What it is | Typical use | Points to know |
|---|---|---|---|
| Flat rack (20ft / 40ft) | A base with end walls (fixed or collapsible), no sides or roof | Wide, tall or heavy machinery, vehicles, boats and steel | Takes heavier loads than a dry box. Cargo can overhang the sides or top, at an extra charge |
| Open top (20ft / 40ft) | A container with a removable tarpaulin roof | Tall items loaded by crane from above | Width is still limited by the container walls |
| Platform | A flat base with no end walls | Very long or wide pieces, sometimes spread across several platforms | Usually loaded as part of a breakbulk-style stow |
| Breakbulk | Cargo loaded directly into the ship's hold or on deck | Very large or heavy pieces beyond container limits | Needs heavy-lift cranes or ship's gear, and careful scheduling |
| Ro-ro | Driven or towed on and off the vessel | Vehicles, plant, buses and cargo on roll trailers | Often the simplest option for anything with wheels or tracks |
As a guide, a 40ft flat rack can carry about 40 tonnes or more, depending on the model. Each carrier and vessel has its own limits for overhang and weight, so every OOG booking is confirmed case by case.
How a project cargo shipment is planned
- Cargo details: exact dimensions (length, width and height), weight, centre of gravity, lifting and lashing points, and drawings or photos.
- Method and equipment: flat rack, open top, breakbulk or ro-ro, based on the cargo, the route and the cost.
- Carrier approval: OOG and heavy cargo needs space and stowage approved by the shipping line before booking is confirmed.
- Route survey: for large loads, a check of the road route at each end for bridges, height limits, weight limits and tight turns.
- Permits and notifications: abnormal load notifications in the UK, and the equivalent permits at origin or destination.
- Loading, lashing and securing: carried out by experienced lashing crews we book and supervise, often with an independent lashing survey and certificate.
- Insurance: marine cargo insurance suited to the value and risk of the goods.
- Delivery and offloading: cranes, forklifts or skates at the delivery site, arranged in advance.
Moving abnormal loads on UK roads
In the UK, loads above certain sizes and weights count as abnormal loads. The haulier must notify the police and, in some cases, road and bridge authorities before the move. The main thresholds are:
| Dimension | Threshold | Notice needed |
|---|---|---|
| Width | Over 2.9 m (standard vehicles) or 3.0 m (special types), up to 5.0 m | 2 working days to the police |
| Width | Over 5.0 m up to 6.1 m | Police notice plus National Highways VR1 permission, applied for at least 2 weeks ahead |
| Length | Over 18.65 m (standard) or 18.75 m (special types) | 2 working days to the police |
| Weight | Over the standard limit, up to 80 tonnes gross | 2 working days to road and bridge authorities |
| Weight | 80 to 150 tonnes gross | 5 working days to road and bridge authorities, and 2 to the police |
| Over 6.1 m wide, 30 m long or 150 tonnes | Special order | Applied for at least 10 weeks in advance |
A summary of the police and National Highways notification rules, for guidance only. Wider or longer loads may also need escort vehicles and set travel times. Your haulier is responsible for the notifications.
- Cargo
- 7.5 m long × 3.2 m wide × 3.1 m high, 18 tonnes
- Too big for a standard container?
- Yes, wider and taller than a high cube door
- Method
- 40ft flat rack, with the machine overhanging the width
- Securing
- Lashed to the rack by specialists, with a lashing certificate
- UK road move
- Over 2.9 m wide, so 2 working days' notice to the police
- Offloading
- Mobile crane booked at the factory for the delivery day
An illustrative example of the planning steps. Real projects are quoted on the cargo's exact dimensions, weight and route.
What affects the cost
- Out-of-gauge surcharges: cargo that overhangs a flat rack can take up the slots of the containers next to it, which carriers charge for
- Specialist equipment availability: flat racks and open tops are scarcer than dry boxes, especially at some origins
- Lifting, lashing and surveys at origin and destination
- Permits, escorts and route surveys for abnormal road moves
- Port handling charges for heavy or OOG cargo, which are higher than for standard containers
- Insurance for high-value or one-off equipment
Why work with us on project cargo
Our shipping line background means we know how carriers approve and stow OOG cargo, and how to get space and specialist equipment when it's scarce. We plan every step in writing before anything moves, book and manage the cranes, lashing crews and abnormal load hauliers ourselves, and stay as your single point of contact from the first drawing to final delivery. We handle project cargo on deep sea routes and across Europe.
Written by the 365 Freight team · Last reviewed . Rates, rules and schedules change, so we'll confirm the details for your shipment when we quote.