How to Ship a Counterbalance Forklift: Weight, Trailers, Securement & Costs

Counterbalance Forklift Weight and Dimensions

Counterbalance forklifts range from small warehouse units to massive industrial machines. The key dimensional challenge is mast height — even with the mast fully lowered, many forklifts are taller than they appear:

Forklift Class	Capacity	Typical Weight	Mast Height (lowered)	Width
Small warehouse forklift	3,000–6,000 lbs	5,000–10,000 lbs	6–7 ft	3.5–4.5 ft
Mid-size industrial forklift	8,000–15,000 lbs	12,000–22,000 lbs	7–9 ft	5–6 ft
Large industrial forklift	20,000–36,000 lbs	30,000–55,000 lbs	8–10 ft	6–8 ft
Heavy-duty container handler	40,000–100,000 lbs	60,000–150,000 lbs	10–14 ft	8–12 ft

Always measure the mast height with the mast fully lowered and tilted back — this is the transport position. The loaded height on the trailer (machine height + trailer deck height) determines whether an oversize permit is required.

Trailer Selection for Counterbalance Forklifts

Trailer selection depends primarily on the forklift's weight and mast height in transport position:

• Dry van trailer: Suitable for small forklifts under approximately 45,000 lbs capacity and under 9 ft 2 in tall (mast lowered). The enclosed environment protects the machine but limits loading options — the forklift must drive in or be lifted in.
• Flatbed trailer: Common for short hauls and smaller forklifts. Standard flatbeds sit approximately 5 ft off the ground, so a forklift with a 7 ft lowered mast will load to approximately 12 ft — within legal limits in most states.
• Step-deck trailer: Recommended for taller forklifts where the loaded height on a flatbed would exceed 13 ft 6 in. The lower main deck (approximately 3.5 ft) provides extra clearance.
• Lowboy or RGN trailer: Required for large industrial forklifts and container handlers. The very low deck height (approximately 18–24 in) accommodates tall masts and heavy machines that would exceed weight limits on standard trailers.

Critical Securement Considerations for Forklifts

Forklifts present unique securement challenges due to their weight distribution and hard rubber or pneumatic tires:

• Positioning: Back the forklift onto the trailer so the forks face away from the cab. This positions the heavy counterbalance weight toward the rear of the trailer, improving weight distribution.
• Centering: The forklift must be centered on the trailer both side-to-side and front-to-back. An off-center load creates dangerous handling characteristics at highway speeds.
• Wheel chocking: Chock all four wheels fore and aft. For hard rubber tires, screw wooden blocks to the trailer floor to prevent rolling — hard tires have no flex and will roll if not positively blocked.
• Tie-down points: Use at least four chains attached to the forklift's frame or designated tie-down points. Never chain to the mast, hydraulic cylinders, or forks. Use padding under chains to prevent paint damage.
• Mast security: The mast must be fully lowered and tilted back. Some carriers add a chain across the mast to prevent it from raising during transit.
• Fuel and battery: Shut off propane valves, disconnect battery terminals, and ensure no fuel leaks before loading.

Permit Requirements

Most standard counterbalance forklifts ship within legal limits on a step-deck or flatbed. Permits are required when:

• Loaded height exceeds 13 ft 6 in (machine height + trailer deck height)
• Machine width exceeds 8 ft 6 in (uncommon for most forklifts)
• Combined GVW exceeds 80,000 lbs (relevant for large industrial forklifts)

Single-trip oversize permits run $35–$125 per state. Large container handlers and heavy-duty industrial forklifts may require multi-axle trailers and overweight permits.

Cost Factors for Forklift Shipping

• Short haul (under 200 miles): $300–$800 for small forklifts on a flatbed; $800–$1,500 for large industrial units
• Regional (200–500 miles): $800–$2,000 for most standard forklifts
• Long haul (500–1,500 miles): $1,500–$4,000 depending on machine size and trailer type
• Cross-country: $3,000–$6,000+ for large industrial forklifts requiring lowboys and permits
• Trailer floor damage: Some carriers charge a surcharge for forklift transport due to the wheel chocking (screws into trailer floor). Disclose this upfront to avoid surprises.

Get a Quote for Your Forklift Shipment

IronHaul Logistics ships counterbalance forklifts of all sizes, from small warehouse units to 100,000-lb container handlers. Our team handles trailer selection, securement planning, and permit coordination. Call (208) 495-2260, email [email protected], or fill out our online quote form for a fast, accurate rate.