How to Ship a Large Excavator (50–100 Ton): Superload Transport Guide

Weight and Dimension Ranges for 50–100 Ton Excavators

Excavators in the 50- to 100-metric-ton class are categorized as large or mining-class machines. Their operating weights significantly exceed the federal 80,000 lb GVW limit for standard highway transport, placing every move in the superload category.

Machine Class	Operating Weight	Typical Width	Typical Height (transport)
50-ton class	100,000–120,000 lbs	11–13 ft	11–13 ft
70-ton class	140,000–160,000 lbs	13–15 ft	12–14 ft
100-ton class	200,000–220,000 lbs	15–18 ft	13–15 ft

These dimensions are for the machine in its transport configuration — counterweights removed, boom and stick detached, and bucket off. In working configuration, these machines are significantly larger and cannot be transported as a single unit.

Superload Classification and Permit Requirements

Any load exceeding 100,000 lbs GVW is typically classified as a superload, triggering a more complex permitting process than standard oversize/overweight moves. Key permit requirements include:

• State-by-state permitting: There is no federal overweight permit. Every state along the route must issue its own permit, with individual fees, travel restrictions, and escort requirements.
• Engineering review: Most states require a structural engineering analysis for superloads to verify that bridges along the proposed route can support the load. This analysis uses the Federal Bridge Formula and state-specific bridge rating data.
• Route survey: A professional route survey is required to identify vertical clearance restrictions (bridges, power lines, overpasses) and horizontal clearance issues (narrow lanes, guardrails) along the entire route.
• Advance notice: Many states require 5–15 business days of advance notice for superload permits. Some require notification to utility companies for power line raises.
• Police escort: Loads exceeding certain width or weight thresholds in many states require a law enforcement escort through urban areas or across critical infrastructure.

Multi-Axle RGN Trailer Requirements

A Removable Gooseneck (RGN) trailer is mandatory for large excavators. The RGN design allows the front gooseneck to detach, enabling the excavator to drive directly onto the trailer deck — critical for machines too heavy to be lifted by crane. For 50–100 ton excavators, multi-axle configurations are required to distribute weight across the road surface and comply with the Federal Bridge Formula.

• 50-ton class: Typically requires a 4–5 axle RGN configuration. Total trailer length with the machine loaded is typically 60–75 ft.
• 70-ton class: Typically requires a 5–7 axle RGN or a jeep/booster combination. Total length may reach 80–90 ft.
• 100-ton class: May require a specialized multi-axle platform trailer with 8–12 or more axles. These moves often require custom trailer configurations and are among the most complex in the industry.

Disassembly Planning for Large Excavator Transport

Partial disassembly is standard practice for 50–100 ton excavators. The goal is to reduce the machine's footprint to the minimum necessary for safe transport while keeping the number of separate loads manageable. Typical disassembly includes:

• Counterweights: Always removed. Counterweights on 50–100 ton machines can weigh 20,000–60,000 lbs each and are shipped on separate flatbeds or step-decks.
• Boom and stick: Detached from the machine body and shipped on separate trailers. Boom sections may be 30–50 ft long and require their own oversize permits.
• Bucket: Removed and shipped separately or nested with the boom sections.
• Track shoes: On very wide machines, individual track shoes may be removed to reduce width. This is labor-intensive but sometimes necessary for route compliance.

A typical 70-ton excavator move involves 3–5 separate loads: the main body on the RGN, counterweights on a flatbed, boom sections on a step-deck, and the stick and bucket on additional trailers.

Route Survey and Bridge Analysis

Every superload move requires a professional route survey before permits can be issued. The survey identifies:

• Vertical clearance restrictions (bridges, power lines, traffic signals) along the entire route
• Bridge weight ratings and whether the proposed load configuration complies with the Federal Bridge Formula
• Horizontal clearance issues (narrow lanes, guardrails, median barriers) that may require traffic control
• Utility company notifications for power line raises or temporary disconnections

Route surveys typically take 3–7 business days and must be completed before permit applications can be submitted. For cross-country moves, multiple route surveys may be required — one per state.

Cost Factors for Large Excavator Transport

Moving a 50–100 ton excavator is among the most expensive heavy-haul operations. Key cost drivers include:

• Multi-axle trailer rental: Specialized multi-axle RGN trailers command premium rates — often $5,000–$15,000 per day depending on configuration.
• Permit fees: Multi-state superload permit packages can run $5,000–$25,000 depending on the number of states and load dimensions.
• Route survey costs: Professional route surveys typically run $1,500–$5,000 per state.
• Escort vehicles: Multiple pilot cars and potentially law enforcement escorts add $2,000–$8,000 to the move.
• Disassembly/reassembly labor: Removing and reinstalling counterweights, boom, and stick requires skilled technicians and can add $5,000–$20,000 to the project cost.

Get a Quote for Large Excavator Transport

IronHaul Logistics has the experience and carrier network to move large excavators safely and legally. Our team manages route surveys, superload permits, multi-axle trailer sourcing, and escort coordination from start to finish. Call (208) 495-2260, email [email protected], or use our online quote form to start planning your large excavator move.