How to Ship a Generator Set (Genset): Complete Transport Guide

Generator Set Classes and Transport Methods

Generator sets are categorized by power output (kW) and physical configuration. Both factors determine the appropriate transport method:

Class	Power Output	Approximate Weight	Configuration	Typical Transport
Portable/Towable	5–150 kW	500–8,000 lbs	Trailer-mounted with axles	Towed behind pickup or flatbed
Mid-Size Skid	150–500 kW	8,000–25,000 lbs	Skid-mounted, no axles	Flatbed or step-deck; crane loading
Large Industrial	500–2,000 kW	25,000–80,000 lbs	Skid-mounted with enclosure	Lowboy or RGN; crane loading
Mega Industrial	2,000+ kW	80,000–200,000+ lbs	Skid-mounted, multi-section	Multi-axle specialized trailer; heavy rigging

Trailer Selection for Generator Transport

Towable generators (with their own axles) can be towed behind a pickup truck or semi for short distances, or loaded onto a flatbed for long-distance transport. When loaded on a flatbed, the generator's tongue must be secured with chains and the wheels chocked.

Flatbed trailers (48–53 ft) work well for mid-size skid-mounted generators (up to ~25,000 lbs) that fit within legal height limits. The generator is crane-loaded onto the flatbed and secured to the trailer's tie-down rails through the skid frame.

Step-deck trailers are preferred for taller generators where the enclosure height plus the flatbed deck height would exceed 13'6". The step-deck's lower rear deck provides more height clearance.

Lowboy and RGN trailers are used for large industrial generators (25,000–80,000 lbs) where weight or height requires the lowest possible deck. The ultra-low deck height maximizes available clearance for tall generator enclosures.

Multi-axle specialized trailers (Goldhofer, Scheuerle) are required for the largest industrial generators (80,000+ lbs). These trailers distribute weight across many axles to stay within per-axle weight limits.

Crane and Rigging Requirements

Unlike most mobile equipment that can drive onto a trailer, skid-mounted generators require crane or forklift loading at both origin and destination. This is a critical planning consideration:

• Lifting points: Most industrial generators have designated lifting lugs or lifting eyes on the skid frame. Never lift a generator by the enclosure panels, exhaust stack, or fuel tank — these are not structural lifting points.
• Crane capacity: The crane must be rated for the generator's weight plus a safety factor. A 50,000 lb generator requires a crane rated for at least 60,000–75,000 lbs at the required radius.
• Rigging: Use certified rigging equipment (chains, slings, shackles) rated for the load. Rigging must be inspected before each lift.
• Site access: The crane must be able to access the generator at both origin and destination. Confirm overhead clearance, ground bearing capacity, and access path width before scheduling.
• Cost: Crane loading at origin and destination adds $500–$5,000+ depending on generator size and crane availability.

Permit Requirements for Generator Transport

Permit requirements depend on the generator's dimensions and weight on the trailer:

• Width: Most generator enclosures are 8–10 feet wide. Loads over 8'6" require a width permit. Loads over 14 feet wide require pilot cars in most states.
• Height: Large industrial generators with tall enclosures (10–14 feet) on a flatbed deck (54 inches) may approach or exceed the 13'6" legal height limit. A step-deck or lowboy reduces this risk.
• Weight: Large industrial generators (50,000–80,000 lbs) on a trailer can push the combination over 80,000 lbs GVW, requiring an overweight permit.

Preparing a Generator for Transport

1. Drain or reduce fuel: Most carriers require fuel tanks at 1/4 or less. Diesel in integral tanks is generally permitted, but full tanks add weight and increase spill risk.
2. Disconnect batteries: Disconnect and secure the battery to prevent accidental starting during transport.
3. Secure enclosure doors: Latch all enclosure doors and panels. Tape or chain them if latches are not secure.
4. Cap open conduit stubs: Cap any open electrical conduit or exhaust stubs to prevent water ingress during transport.
5. Document pre-existing condition: Photograph all sides, including the control panel, exhaust system, and any pre-existing damage.
6. Confirm lifting points: Identify and mark the manufacturer-designated lifting lugs for the crane operator.

Cost Factors for Generator Transport

• Distance: Long-haul moves (500+ miles) typically run $2.50–$5.00/mile for flatbed transport of a mid-size generator.
• Crane loading: $500–$5,000+ at origin and destination depending on generator size.
• Permit costs: $50–$500 per state depending on dimensions and weight.
• Specialized trailer: Lowboy and multi-axle trailers cost significantly more than standard flatbeds.
• Emergency/expedited service: Storm recovery and critical infrastructure failures often require expedited generator transport — IronHaul offers expedited service for time-sensitive moves.

IronHaul Logistics ships generator sets of all sizes nationwide — from portable towable units to large industrial standby generators. We coordinate crane loading, permit procurement, and specialized trailer selection. Call (208) 495-2260, email [email protected], or request a quote online.