How to Ship a Forklift: Trailer Selection, Securement & Permit Guide
Forklifts look simple to ship—they're compact, self-propelled, and don't have booms or tracks to worry about. But their high center of gravity, counterbalanced weight distribution, and tall masts create real challenges for trailer selection and securement. A 10,000-lb warehouse forklift and a 100,000-lb heavy-duty industrial lift require completely different approaches. This guide covers everything you need to know before booking a forklift shipment.
Forklift Weight and Size Categories
Forklifts span an enormous range of sizes. Understanding where your machine falls determines the trailer type, tow vehicle requirements, and whether you'll need oversize permits:
| Category | Operating Weight | Typical Mast Height (lowered) |
|---|---|---|
| Mini / Warehouse (electric) | 3,000–6,000 lbs | 6–8 ft |
| Standard Counterbalanced | 6,000–15,000 lbs | 7–10 ft |
| Large Counterbalanced | 15,000–35,000 lbs | 8–12 ft |
| Heavy-Duty Industrial | 35,000–100,000+ lbs | 10–16 ft |
| Rough Terrain Forklift | 10,000–30,000 lbs | 10–14 ft |
Choosing the Right Trailer
Standard Flatbed (48 ft or 53 ft)
Suitable for most warehouse and standard counterbalanced forklifts weighing under 15,000 lbs with mast heights under 8.5 ft when lowered. The flatbed deck sits approximately 5 ft off the ground, leaving roughly 8.5 to 9.5 ft of vertical clearance under the 14 ft legal height limit. If your forklift's mast exceeds this clearance when lowered, you'll need a lower-deck trailer.
Step Deck (Drop Deck)
The step deck's lower rear section (typically 3.5 ft off the ground) provides an additional 18 inches of vertical clearance compared to a standard flatbed. This makes it the right choice for forklifts with mast heights of 9 to 11 ft when lowered, or for machines that are slightly over the flatbed height limit.
Lowboy / RGN (Removable Gooseneck)
The lowboy deck sits just 18 to 24 inches off the ground, providing maximum vertical clearance for tall masts. RGN trailers allow the front gooseneck to detach, enabling the forklift to drive directly onto the deck—eliminating the need for ramps or cranes. This is the required trailer for heavy-duty industrial forklifts over 35,000 lbs and any machine with a mast that cannot be lowered below 11 ft.
Securement Requirements (FMCSA § 393.130)
DOT regulations require a minimum of four tie-downs for any wheeled equipment over 10,000 lbs, with an aggregate Working Load Limit (WLL) of at least 50% of the cargo weight. For a 20,000-lb forklift, your combined tie-down WLL must be at least 10,000 lbs.
Critical securement rules for forklifts:
- Chains must attach to the main frame or chassis—never to the mast, overhead guard, or lift arms
- Lower forks completely to the deck and tilt the mast slightly forward before securing
- Bind forks together with heavy-duty straps or chains to prevent independent movement
- Set the parking brake and place the transmission in neutral or park
- Disconnect the battery on electric forklifts to prevent accidental startup
- Secure or remove propane tanks on LP-gas forklifts
Permit Requirements
Most standard warehouse forklifts ship within legal dimensions and don't require oversize permits. However, heavy-duty industrial forklifts frequently exceed legal limits:
- Width over 8.5 ft: Oversize permit required in all states
- Height over 13.5–14 ft (including trailer deck): Oversize permit required
- GVW over 80,000 lbs: Overweight permit required
A 60,000-lb industrial forklift on a lowboy trailer (trailer weight ~35,000 lbs, tractor ~20,000 lbs) will typically exceed the 80,000-lb GVW threshold and require overweight permits in every state on the route.
Preparation Before Pickup
- Confirm exact operating weight (including any attachments) and mast height when fully lowered
- Check for hydraulic leaks—carriers may refuse to load a machine that is actively leaking
- Ensure the machine can move under its own power, or notify the carrier in advance if it cannot (inoperable surcharges apply)
- Photograph the machine from all angles before loading for insurance documentation
- Confirm site access at both pickup and delivery—lowboy trailers require more turning radius than standard flatbeds
Ship Your Forklift with IronHaul
IronHaul Logistics moves forklifts of all sizes, from compact electric warehouse units to 100,000-lb heavy industrial lifts. We select the right trailer, handle all permit requirements, and coordinate certified escorts when needed. Call (208) 495-2260, email [email protected], or use our online quote form to get a rate for your forklift shipment.
Common questions
What trailer do I need to ship a standard warehouse forklift?
Most standard counterbalanced forklifts (6,000–15,000 lbs) with mast heights under 8.5 ft when lowered can ship on a standard flatbed. If the mast is taller, a step deck or lowboy provides the additional vertical clearance needed.
Can I ship a forklift with the mast raised?
No. The mast must be fully lowered for transport. Most forklifts have a mast height of 6 to 16 ft when lowered—this is the dimension that determines trailer selection and whether an oversize permit is required.
Do I need a permit to ship a forklift?
Standard warehouse forklifts typically ship within legal dimensions and don't require permits. Heavy-duty industrial forklifts over 35,000 lbs, or any forklift that exceeds 8.5 ft wide or 13.5 ft tall (including trailer deck height), will require oversize or overweight permits.
How do I secure a forklift for transport?
FMCSA regulations require a minimum of four tie-downs attached to the main frame or chassis—never to the mast or overhead guard. Forks must be lowered to the deck, the parking brake set, and the battery disconnected on electric models. The aggregate Working Load Limit of all tie-downs must equal at least 50% of the forklift's weight.
What if my forklift can't move under its own power?
Inoperable forklifts can still be transported, but the carrier needs to know in advance. Loading an inoperable machine typically requires a crane or forklift at the pickup site, and carriers charge an inoperable surcharge to cover the additional equipment and time.
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