How to Ship a Large Crane: Disassembly, Permits, and Transport Planning

Types of Large Cranes and Their Transport Complexity

Not all cranes are equally complex to transport. Understanding your crane type determines the scope of the move:

Lattice Boom Truck Cranes

Lattice boom truck cranes are mounted on a road-legal carrier chassis and can travel between job sites at highway speeds with minimal disassembly. Typical transport requirements:

• The carrier chassis is road-legal and can self-transport (with appropriate permits for width and weight)
• Boom sections are typically removed and transported on separate flatbed or step-deck trailers
• Counterweights may need to be removed to reduce axle weights for highway travel
• Disassembly and reassembly typically takes hours, not days
• Total truck loads: typically 2–5 for a mid-size lattice boom truck crane

Crawler Cranes

Crawler cranes are the most complex to transport. They cannot travel on public roads under their own power and must be fully disassembled for transport. A large crawler crane (200–500 ton class) may require:

• Carbody: The main body of the crane, transported on a multi-axle lowboy or modular trailer
• Tracks: Each track section transported separately on a lowboy or flatbed
• Superstructure: The rotating upper works, transported on a multi-axle lowboy
• Counterweights: Multiple counterweight slabs, each transported on a flatbed or lowboy
• Boom sections: Multiple lattice boom sections, each transported on a flatbed or step deck
• Assist crane: A smaller crane is required at both origin and destination to disassemble and reassemble the main crane
• Total truck loads: 10–30+ for a large crawler crane

Tower Cranes

Tower cranes are disassembled into mast sections, jib sections, and the slewing unit for transport. They are typically lighter than crawler cranes but require careful handling of the mast sections, which can be 20–40 feet long and awkward to secure.

Boom Section Transport: The Most Common Crane Shipping Challenge

Boom sections are the most frequently shipped crane component, often moved separately from the crane itself when a crane is relocated between job sites. Key considerations:

• Length: Individual boom sections are typically 10–40 feet long. Multiple sections are often bundled together on a single flatbed or step-deck trailer.
• Weight: Lattice boom sections are relatively light (500–5,000 lbs per section) but awkward to handle due to their length and irregular shape.
• Blocking and cribbing: Boom sections must be properly blocked and cribbed to prevent bending or twisting during transport. Use hardwood blocking at manufacturer-specified support points.
• Tie-down points: Secure at the chord members (main structural tubes), not at the lattice diagonals, which are not designed for tie-down loads.
• Overhang: Long boom sections may overhang the trailer's rear. Federal regulations allow up to 4 feet of front overhang and up to 6 feet of rear overhang without a flag; longer overhangs require flags and may require permits.

Permit Requirements for Crane Transport

Large crane components almost always require oversize and/or overweight permits:

• Carbody and superstructure: These are typically the heaviest components and almost always require overweight permits. A 300-ton crawler crane's carbody alone may weigh 100,000–200,000 lbs, requiring a modular trailer and superload permits.
• Tracks: Each track section may weigh 20,000–80,000 lbs and require overweight permits depending on the crane size.
• Counterweights: Individual counterweight slabs typically weigh 10,000–50,000 lbs each. Multiple slabs may be stacked on a single trailer if total weight allows.
• Boom sections: Usually within standard weight limits but may require length permits if sections are very long or if multiple sections are bundled to exceed 53 feet.
• Superload permits: For the heaviest components (carbody, superstructure), superload permits are required in most states. These require route surveys, engineering analysis, and advance coordination with state DOT offices — plan 4–8 weeks ahead.

Planning Timeline for a Large Crane Move

A large crawler crane move requires significant advance planning:

• 8–12 weeks before move: Identify all components to be moved, get weights and dimensions from the crane manufacturer or owner's manual, begin superload permit applications for the heaviest pieces
• 6–8 weeks before move: Confirm carrier availability, book multi-axle trailers and modular trailers for heavy components, schedule assist crane at origin and destination
• 4–6 weeks before move: Complete route surveys for superload components, finalize permit applications, confirm escort vehicle requirements
• 2–4 weeks before move: Confirm all permits are approved, brief all carriers on component-specific loading and securement requirements
• 1 week before move: Confirm all logistics, verify weather forecast, confirm assist crane availability at origin

Choosing the Right Carrier for a Crane Move

Not all heavy-haul carriers have experience with crane moves. When selecting a carrier, look for:

• Experience with multi-component crane moves (ask for references)
• Access to multi-axle lowboys and modular trailers for heavy components
• In-house permit coordination capability (not outsourced)
• TWIC-credentialed drivers if the crane is moving to or from a port
• Ability to coordinate multiple trucks moving simultaneously for convoy moves

Ready to Plan Your Crane Move?

IronHaul Logistics coordinates large crane moves nationwide, from single boom section shipments to full crawler crane relocations. We handle superload permits, route surveys, multi-axle trailer coordination, and convoy logistics. Call (208) 495-2260, email [email protected], or use our online quote form to start planning your crane move.