The choice between flat rack vs container often determines the project budget, transit time and transport risk. While standard box containers have been the logistics gold standard for decades, flat rack containers are now indispensable when width, height or weight exceed classic 40 ft dimensions. This guide looks at all the relevant factors - from dimensions and load handling to insurance and customs - to help you make an informed flat rack vs container decision.
Six steel walls or open ends? For machine builders, vehicle dealers or project logistics companies, container design not only influences freight costs, but also route freedom, the use of loading equipment and risks en route. If an excavator that is too large is placed in a box container, there is a risk of oversize surcharges, lifting gear bottlenecks and even cargo damage due to incorrect load distribution. If, on the other hand, you opt for a flat rack, crane use is added - but excess height is suddenly no longer a problem. In short: the distinction between flat racks and containers saves money and nerves.
Deepening: RoRo vs flat rack - a comparison of methods
| Feature | Standard container (20/40 ft) | Flat rack container (20/40 ft) |
|---|---|---|
| Structure | Four side walls + roof | Front and base frame, open |
| Payload (guide value) | up to ≈ 28 t | up to ≈ 45 t (heavy-duty type) |
| Inside width/height | 2.34 m / 2.38 m | open; excess width > 3.6 m, height > 4 m |
| Handling | Forklift trucks, reach stackers, cranes | Cranes, heavy-duty spreaders, lash gear |
| Protection | Weather & theft protection | open - shrink wrap/VCI film recommended |
| Typical load | Cartons, pallets, vehicles (CKD) | Transformers, boats, excavators, lorries, etc. |
(Suggested image: comparative graphic flat rack vs box container; old text "Flat rack without side walls next to 40 ft box container")
Conclusion: Box containers are ideal when cargo is compact, weather-sensitive and of high quality.
Practical example & safety tips: Checklist for RoRo shipping
| Risk | Box container | Flat rack | Preventive measure |
|---|---|---|---|
| Weather conditions | low | high (salt spray, rain) | Shrink wrap, VCI film |
| Theft | low | medium | 24/7-Yard, GPS-Seal |
| Charge displacement | low | high with incorrect lashing | FEM lashing plan, survey |
| Harbour dues | Standard | Heavy-Lift/Out-Gauge | Advance tariff check |
| Insurance | ICC A, standard premium | All risk + surcharge | Value +10 % cover |
External guideline: IMO/ILO/UNECE CTU Code for Cargo Units (PDF, MSC.1/Circ.1497)
(Note: personal enquiry recommended for specific costs).
| Question | Answer | Recommendation |
|---|---|---|
| Does the load exceed 2.44 m in width? | Yes | Flat rack |
| Does the load exceed a height of 2.60 m? | Yes | Flat rack |
| Weather protection mandatory? | Yes | Box container |
| Weight ≤ 28 tonnes? | Yes | Box container |
| Crane & Lash team available? | No | Container or RoRo |
| Project deadlines tight? | Yes | Box container |
| Step | Measure | Done |
|---|---|---|
| Surveying | Determine exact L×W×H & weight | ☐ |
| Check CTU code | Apply packing & securing guidelines | ☐ |
| FEM lashing plan | Commission surveyor from > 20 tonnes | ☐ |
| Corrosion protection | Obtain shrink wrap/VCI film | ☐ |
| Insurance | Take out an all-risk policy | ☐ |
| Harbour handling | Book crane, spreader, trailer | ☐ |
Is a flat rack always stowed on deck?
No, often also below deck - depending on the stowage plan and the stability calculation.
Do I need special documents for Flat-Rack?
From around 20 tonnes, a certified FEM lashing plan is required, supplemented by load sketches and photos.
Can I combine several flat racks?
Yes - "twin racks" up to 12 m wide are possible, but require shipowner and harbour approvals.
Are there weight limits per harbour crane?
STS cranes usually lift ≥ 65 tonnes; smaller ports are sometimes below this - check beforehand.
The decision between flat racks and containers depends on dimensions, weight, protection requirements and port infrastructure. Oversized, heavy or bulky goods travel more safely in a flat rack - provided the lashing plan, corrosion protection and crane capacity are right. Standard containers score points with weather protection, simple handling and often lower handling costs. ODS Orient advises on measurement, load capacity and route selection - so that your project reaches its destination on time and on budget.
All information in this article has been carefully researched but is subject to change at any time. ODS Orient accepts no liability for the topicality, accuracy or completeness of the content provided.
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