Heavy haulage explained: Definition, costs, regulations, and transport process

Looking to move oversized or overweight cargo? Think wind turbine blades, huge construction machinery, or power station generators. That’s heavy haulage. This guide breaks down what it is, how it works, the equipment involved, compliance requirements, and best practices to follow.

What is heavy haulage?

Heavy haulage is the transportation of cargo that exceeds standard legal limits for size, weight, or height. These loads cannot be moved by regular trucks and require special equipment, routing, and permits.

Before we go further, here’s what we mean by:

• Oversized cargo: Too wide, tall, or long for standard road transport
• Overweight cargo: Exceeds the legal maximum weight for a vehicle on a public road
• Out-of-gauge (OOG): Cargo that doesn’t fit within the dimensions of standard containers or trailers

Also referred to as heavy haul trucking or heavy hauling, this process typically involves transporting oversized, overweight, or OOG loads using heavy haul trucks and specialised trailers.

When do you need heavy haulage?

While exact regulatory thresholds vary by location, here are the typical limits that trigger the need for a heavy haulage solution. If your load is bigger than these general limits, special rules kick in:

Note: These limits can vary by country, state, or even individual roadways. Different logistics providers will also have different specifications. Always check local regulations before planning a heavy haulage move.

Which industries use heavy haul services?

Heavy haul trucking supports sectors that rely on large, heavy, or unusually shaped equipment:

• Construction: Cranes, bulldozers, prefabricated structures
• Energy and utilities: Transformers, turbines, generators, reactors
• Oil and gas: Drilling rigs, pipelines, offshore equipment
• Manufacturing: Oversized industrial machinery
• Wind energy: Blades, towers, nacelles
• Aerospace: Aircraft fuselages, components

Moving the haul: The process of heavy haul trucking

The heavy haul process involves multiple steps that require precision and coordination:

1. Planning and permits: The process starts with obtaining the necessary permits based on the most suitable equipment and travel route for the cargo.
2. Route planning: A route is mapped that considers clearance, bridge weight limits, local restrictions, and potential obstacles.
3. Loading and securing: Specialised cranes or forklifts are used to load the cargo, which is then secured using heavy-duty tie-downs to prevent shifting.
4. On the road: The heavy haul vehicle travels the planned route, and – if deemed necessary during the permit application and route planning process – is accompanied by one or more escort vehicles for safe and legal road haulage.
5. Unloading and delivery: At the destination, the cargo is safely offloaded using the appropriate lifting equipment.

Equipment used in heavy hauling

Transporting oversized cargo requires more than just a trailer. It involves:

• Heavy haul trucks: Multi-axle, high-powered vehicles built to carry extreme loads
• Specialised trailers: Lowboys for tall loads, extendable flatbeds for long components
• Lifting equipment: Cranes, dollies, and forklifts for loading and unloading
• Pilot/escort vehicles: Depending on the cargo dimensions, route, and local regulations, a lead (pilot) vehicle is often required to manage speed, safety, and traffic flow. Some jurisdictions also require a rear escort car for particularly large or complex hauls.

Costs involved in heavy haul trucking: What to expect

Heavy haul costs vary depending on load size, travel distance, permits, and route complexity. Here's what to consider:

• Permits: Required per state/country/region and based on weight and dimensions
• Fuel: High fuel consumption due to the vehicle’s size and load weight
• Pilot/escort vehicles: Costs add up when multiple escort vehicles are needed
• Skilled labour: Certified drivers and riggers are essential

Compliance and documentation for heavy haul

Understanding legal compliance requirements is essential. Regulations vary by region, and failing to follow them can lead to delays or fines.

• Weight and size limits: Every region regulates 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 outline the route the vehicle can take. This considers factors like bridge clearances, road capacity, and potential traffic disruptions.
• Safety standards: Heavy haul operations are subject to strict safety regulations. These cover vehicle maintenance, load securement, and escort car protocols.

Also, to stay compliant and avoid delays or fines, your heavy haul shipment will likely need these documents:

• Oversize/overweight cargo permits (state/region-specific)
• Bill of lading (B/L)
• Load securement checklist
• Proof of insurance

How is heavy haulage different from project logistics?

Heavy haulage is sometimes confused with broader logistics planning. Here's the difference:

Imagine building a house. Heavy haulage is like delivering the giant crane needed for construction. Project logistics is the full plan for getting all the materials – bricks, beams, tiles – to the right place at the right time.

Can heavy haul be intermodal or multimodal?

Heavy haul loads don’t just travel by road. In many cases, your shipment forms part of an intermodal or multimodal setup combining two or more modes of transport. Typical combinations include:

• Truck + Rail: Ideal for long inland routes, heavy or oversized cargo is moved on specialised railcars (e.g. flatcars or depressed-center cars), with trucks handling first/last-mile transport.
• Truck + Barge: Common on inland waterways, barges move very heavy or out-of-gauge loads efficiently, supported by trucks at each end.
• Truck + Ocean: For international shipments, trucks deliver to ports where cargo is loaded onto roll-on/roll-off or breakbulk vessels for ocean transit.

Combining modes helps reduce costs, overcome infrastructure limits, and enable complex logistics for oversized loads.

Need help with your heavy haul cargo?

At Maersk, we have extensive expertise to handle every aspect of heavy haulage transport – from planning and securing permits to safely offloading your special cargo at its final destination. We offer both heavy haulage execution and full-scale project logistics support for your varying transportation needs.

If your cargo needs to cross multiple geographies or modes, Maersk can help you simplify the journey with a tailored heavy haul strategy that works across borders and transport types. Learn more about our end-to-end special transport services.