When it comes to shipping, accurate measurements aren’t a nice bonus — they’re the baseline of your supply chain’s success.
It might sound dramatic, but it's true: Precise load measurements lay the groundwork for everything from trailer type to safety to cost-efficiency.
Unfortunately, mistakes in these measurements are all too common, and the repercussions can ripple through the entire shipping process, causing delays, added costs, and even safety hazards.
In the 70 years that Anderson Trucking Service (ATS) has been in the transportation industry, we’ve taken note of the freight measurement mistakes shippers often make without realizing.
Our experience helping shippers rectify these issues and transport freight of all shapes and sizes allows us to offer expert advice on avoiding these pitfalls in the future.
This article will identify seven of the most common freight measurement mistakes and dig into why they’re problematic for both shippers and carriers.
Along the way, we’ll provide steps you can take to avoid them in your own operations, so you can support smoother, more reliable transportation that benefits everyone involved.
So, bust out your tape measure and scale, and let’s get started!
Why Do Accurate Freight Measurements Matter to Carriers?
Freight measurements are the foundation of many decisions made by a transportation provider, from the rate to the trailer type to the packaging needs.
Accurate weight and dimensional measurements help carriers:
- Ensure compliance with legal weight limits, avoiding costly fines and preventing vehicle damage or accidents.
- Determine what type of trailer is most appropriate for transportation and what packaging is needed.
- More effectively plan optimal load distribution, which directly affects fuel efficiency and safety on the road.
- Maximize space, which improves load planning and profitability by reducing the number of trips needed.
- Streamline the logistics process by preventing delays from re-weighing, reloading, or the need for modified permits.
Ultimately, when shippers provide accurate load measurements to their carriers, they are increasing the likelihood of efficient, reliable service and a satisfactory customer experience.
The Most Common Freight Measurement Mistakes
Let’s get the little stuff out of the way first: A shipper mislays a comma and turns a 2,500-pound load into a 25,000-pound one, a carrier mistakes a 1 for a 7 or a 9 for an 8 . . . these kinds of simple documentation mistakes are common.
Luckily, that means carriers are used to them, and are generally understanding about the occasional misplaced decimal or zero.
These types of gaffes are also much easier to spot early on in the process than some of the issues we’re about to address.
We’ve broken down some of the most common freight measurement mistakes to help you visualize how they can occur, understand why they’re problematic, and learn ways to avoid them:
- Overloading trailers with freight
- Confusing dimensional weight and actual weight
- Adding pounds via packaging
- Misunderstanding dimensional maximums
- “It’s just one inch!”
- Forgetting modifications
- Intentional lowballing
Overloading Trailers
One of the most common errors shippers make when creating a load plan is putting too much weight on a trailer.
In an effort to squeeze the most value out of a single truckload, shippers often overload trailers without paying attention to legal axle weight limits.
Load weight must also be evenly distributed over each axle for optimal fuel efficiency and safety; a poorly distributed load can become dangerous in situations like inclement weather, but shippers may overlook (or simply not be aware of) this risk.
Dimensional Weight vs. Actual Weight
Another common discrepancy is the difference between a shipment’s dimensional weight and actual weight.
In shipping, dimensional weight refers to an estimated weight calculated from the length, width, and height measurements of a product or load. Dimensional weight does not factor in packaging.
Actual weight is exactly what it sounds like — the actual weight of the shipment, including any packaging like pallets, blanket wraps, etc.
An awareness of both these measurements can be critical, particularly when shipping cargo with a dimensional weight that is approaching the over-dimensional (OD) threshold.
Medical equipment, for example, is extremely sensitive to shock. Shipping this cargo safely and effectively requires heavy-duty pallets, shock absorbers, and pad wrap — additions that can quickly add up to hundreds of pounds of actual weight and tip the shipment over into OD.
Adding Pounds via Packaging
Speaking of packaging, it’s a common culprit when it comes to hidden weight.
Shippers often forget to factor in the weight of pallets, crates, wraps, blankets, and other packaging elements when providing dimensions to their carriers.
This is especially tricky, because each packaging type can have variable weights from one manufacturer to the next depending on the materials used and how they were fabricated.
Wood pallets, for example, are popular for their low cost but can vary wildly in weight based on the type of wood used.
Some shippers opt for plastic pallets for this reason; while plastic is a considerable investment compared to wood, it is significantly more consistent in weight and is reusable for much longer.
Likewise, there’s no need to use high-quality (read: heavier) wood to build a crate that only needs to survive a single shipment. A lesser, lighter wood will not only cost less but also have a much smaller impact on actual weight.
Packaging is a largely unavoidable addition to your freight’s dimensions (unless you’re shipping breakbulk, of course!) but by staying aware of its impact and weighing your freight post-packaging, you can avoid surprises at the scale.
Misunderstanding Dimensional Maximums
All trailer types are unique in their own way, and some have more complex considerations than others. As freight approaches the maximum height, length, and/or width measurements for a given trailer type, things can get a little sticky.
While a shipment may technically measure under the maximum load dimensions for your trailer of choice, shippers aren’t always aware of the nuances of that trailer — nuances that can present a problem in practice.
Take Conestoga trailers, for example: Let’s say a Conestoga has a height maximum of 8 feet. If your cargo measures 7 ft. 2 in. tall, you might think you’re in the clear — you’re under 8 feet, so what’s the problem?
Well, when the retractable tarps of a Conestoga are rolled up to allow for freight loading and unloading, that eats up some of the overhead clearance within the trailer itself. Suddenly the shipment you thought was a perfect fit can’t even fit through the door!
You also have to mind your length and width on a Conestoga — you don’t want to risk ripping that tarping on a sharp edge or corner of your shipment!
But Conestogas are just one example of a trailer with type-specific considerations.
Step-deck and removable gooseneck (RGN) trailers also throw shippers for a loop due to the difference in measurement maximums per deck.
The good news is that an experienced transportation provider should catch these potential issues before any trucks are dispatched to your pick-up.
But it’s still important for shippers to be aware of when their freight is approaching the maximum measurements for their preferred trailer type, and to ask for their carrier’s advice when selecting trailers.
Lean on the expertise of your network of trusted, well-vetted transportation providers. They’ll steer you in the right direction to ensure your freight ends up on the right trailer for the job.
“It’s Just One Inch!”
All too often, we see shipments become over-dimensional by length, width, or height due to the shipper underestimating the impact of “just one inch.”
When a shipment exceeds the dimensional limits for freight to travel legally, it becomes an over-dimensional (OD) load. OD freight requires permits to move safely and legally, so carriers rightfully take dimensional restrictions seriously.
Overages represent not just a permitting issue, but a safety issue for the driver, the cargo, the infrastructure of the roads it will be traveling on, and the motoring public with whom the truck will share the road.
So, while “just one inch” may seem negligible on paper, when a shipment gets stuck in a tunnel or hits the overhead clearance of a bridge, things can get serious — and dangerous — fast.
It’s critical that shippers resist the urge to let an extra inch here or there squeak by undocumented. Precise, thorough measurements are your first line of defense against fees, delays, and accidents.
What’s more, by accurately reporting your shipment’s measurements at the outset, you’ll save yourself from delays spent waiting for the permit office to issue a modified permit for your freight’s actual dimensions.
If a shipment you previously believed to be within legal dimensional limits has become over-dimensional unexpectedly, consult with your transportation provider.
They’ll be able to help you determine whether your shipment can travel on a different trailer type, be divided into smaller, separate loads, or benefit from a creative solution developed specifically for your freight.
Mind Your Modifications
If you regularly ship OD freight (especially pieces that are typically modified or customized, like heavy haul equipment), be careful not to fall into the trap of defaulting to manufacturer specifications rather than the true dimensions of the actual piece you’re shipping.
Imagine a carrier expects to pick up a standard bulldozer from a shipper, but discovers upon arrival that there’s been a modification — a 13-foot-wide blade, which adds width and weight. What’s more, the gas tank is full, adding even more weight to the shipment.
Forward movement on that shipment must come to a screeching halt as the carrier rushes to get updated permits.
Those discrepancies can quickly add up, both in terms of time wasted and money spent.
To avoid this pitfall, always double-check that any customizations or modifications have been accounted for in the dimensions provided to your carrier. Oh, and check the gas tank of any self-propelled equipment! Additional weight can hide in plain sight.
Ultimately, when in doubt, measure again. It might seem tedious, but it’s always better to be safe than sorry.
Intentional Lowballing
Finally, in rare cases, some shippers will knowingly misstate the dimensions of a shipment in an attempt to avoid paying higher rates or acquiring OD permits.
This is a poor practice, both in terms of the shipper’s business relationship with their carrier and as a steward of their own company’s best interests.
Imagine a scenario in which a shipper tells a carrier their product weighs 2,000 pounds. The carrier takes the shipper at their word and assigns a driver to the load, which is loaded onto a truck at the shipper’s facility.
Unfortunately, no one notices that the shipment actually weighs 8,500 pounds — but the receiver whose forklift can’t lift that product sure does! Now the truck can’t be unloaded, the shipment is stranded, and the carrier loses time and money scrambling to find a solution.
And it’s not just the carrier that’s stressed out and inconvenienced by the shipper’s deception.
The shipper will likely end up footing all (or the majority portion) of the bill for the extraordinary measures the carrier had to take to resolve the issue, possibly with additional fees to compensate for all the headache and hassle.
The shipment could be significantly delayed or even sent back to the pick-up location, resulting in additional costs and supply chain slow-downs.
Suffice it to say, it’s in no one’s best interest to lie about a shipment’s dimensions. It can result in serious issues for all parties involved, especially if the discrepancy isn’t caught early.
Always provide your carrier with the most accurate measurements possible to ensure the safe, seamless transportation of your freight. It’s the right thing to do, both for your company and your relationship with your provider.
Ensure Your Freight Can Travel Seamlessly — at Any Size
No matter the size of your freight, getting your load measurements right isn’t just about satisfying your carrier’s requirements — it's key to making sure your shipment arrives smoothly, on time, and without surprise costs.
When it comes to avoiding the most common freight measurement mistakes we’ve outlined in this piece, it would be easy to tell you to take a “measure twice, cut once” approach and leave it at that.
But the truth is that even if you faithfully double-check the dimensions of every shipment, some things will still get missed.
We’re only human, after all; errors and misunderstandings are going to happen from time to time. But you can set yourself and your carrier up for success by leveling up your proactivity and diligence in your pre-shipment preparations.
So, yes, double-check your measurements — and compare them to your trailer type of choice, consider the impact of packaging, keep an eye out for modifications, and maintain open, honest communication with your carrier.
These steps won’t just help you avoid the most common freight measurement mistakes and minimize hassle, they’ll also actively enhance your supply chain’s efficiency and reliability.
Want a refresher on the basics of pre-shipping preparation? Check out our article on How to Prepare Freight for Shipping.
It breaks down everything you need to know about thoroughly specifying the dimensions and requirements of your freight prior to shipping.
You’ll walk away fully equipped to prepare your shipments for pickup by your transportation partner, helping to facilitate a smoother, more successful process for all involved.
