A strong crate doesn’t guarantee a safe delivery. Most transit damage happens inside the box: cargo that shifts, vibration that loosens fittings over hundreds of kilometres, and condensation that builds up in a sealed container at sea. The outer shell takes the knocks, but what you do inside it decides whether your product arrives in the condition it left.
Here’s what causes damage in transit, and how to prevent each problem.
Where Transit Damage Comes From
Damage comes from a few predictable sources:
- Movement. Any gap between the cargo and the crate lets the load slide, tip or hammer against the walls every time the truck brakes or the crate is lifted.
- Vibration and shock. Long road trips on uneven surfaces cause constant low-level vibration. Forklift handling and loading cause sudden shocks.
- Moisture. Temperature swings in containers and holds cause condensation, which leads to rust on machinery and mould on organic materials.
- Poor weight distribution. A heavy item sitting on the wrong part of the base creates a weak point that can crack the floor or make the crate unstable when lifted.
- Incorrect handling. If handlers can’t tell which way is up or where to lift, they’ll guess.
Every good crate design addresses all five.
Blocking and Bracing: Stop the Load from Moving
The most important rule is that the cargo must not move inside the crate.
- Fix heavy items to the base. Machinery should be bolted or strapped down to the skid so the item and the base move as one unit.
- Block the sides. Timber blocks fixed to the base, tight against the cargo, prevent sliding forwards, backwards and sideways.
- Brace from above. Cross-braces between the walls hold tall or top-heavy items in place and stop them from tipping.
- Fill the voids. Any remaining space should be packed so nothing can shift.
Foam and bubble wrap help with surface protection, but they won’t hold a heavy load in place. For anything substantial, timber blocking and bracing does the real work.
Build the Base for the Weight
The base carries the full load and takes every forklift lift, so it’s where crates most often fail.
- Size the runners and floor for the heaviest point, not just the average weight.
- Allow forklift and pallet-jack access on the sides that handlers will use.
- Position the load near the centre so the crate lifts level. Where that isn’t possible, mark the centre of gravity on the outside.
Cushion Fragile Items Correctly
Delicate equipment needs a combination of firm support and shock absorption:
- Support the item at its strongest points, not across delicate panels or fittings.
- Use cushioning between the item and any rigid surface it could contact.
- Wrap or cover exposed surfaces to protect against abrasion from vibration.
Control Moisture
Sea freight and long storage periods carry the highest risk. Common measures include:
- A vapour barrier bag sealed around metal equipment
- Desiccant packs inside the barrier to absorb trapped moisture
- Ventilated or slatted designs for products that need airflow
Ask your crate supplier which approach suits your product and route.
Match the Crate to the Transport Mode
- Road freight: prioritise bracing against vibration over long distances.
- Sea freight: prioritise moisture protection and stacking strength.
- Air freight: keep weight down. Lighter plywood or Masonite crates are often used to reduce freight costs.
Exporting? Check Packaging Requirements
Timber packaging that crosses international borders generally needs to be treated and marked under the ISPM 15 standard. Confirm the destination country’s requirements and your crate supplier’s compliance before you ship, so your consignment isn’t held at customs.
Mark the Outside Clearly
Simple markings prevent a lot of avoidable damage:
- This Way Up arrows
- Fragile labels where relevant
- Centre of gravity and lifting points for heavy loads
- Consignee and handling details
Get It Right from the Start
Bruben Timbers builds custom wooden shipping crates around the exact size, weight and destination of your cargo. That way the protection inside the crate is planned in, not added as an afterthought.
To get an accurate quote, have the following ready:
- Inside dimensions required (length × width × height)
- The weight of your product
- The planned destination
We can also arrange a site visit to measure your cargo and confirm requirements before we build.
Contact Bruben Timbers to discuss your next shipment.
