By Cadys Wang    Photo：CANVA

Last time, we talked about choosing between a Flat Rack and Breakbulk, which often comes down to how you want your cargo to travel through the global infrastructure.

Let’s review the content using the questions below; the answers will be at the end of this blog.

1. Dimensions and Weight: Does your cargo exceed the width or height of a standard 40ft container, but still weigh less than 45 tons?
2. Origin/Destination: Are you shipping between major container ports, or is one of the ports a smaller, specialized industrial terminal?
3. Onward Transport: Once the ship arrives, do you need the cargo to move immediately onto a truck or train for inland delivery?

Today, we will dig deeper into how to handle Flatracks and Open-Tops Cargo in 2026

In logistics, we’re wired to love standardization.

Standard containers.

Standard workflows.

Standard timelines.

They make the world predictable—and efficiency thrives on that.

But every once in a while, a shipment comes along and reminds us of a simple truth:

Not everything is designed to fit inside a box.

Oversized machinery.

Long steel structures.

Irregular industrial components.

These cargos don’t “break the rules”—

they were never meant to follow them in the first place.

As we head into 2026, I’ve noticed more shippers asking the same question:

“Do we really need to go full breakbulk, or is there a smarter middle-ground?”

That’s exactly where Flatrack and Open-Top containers come into play.

They’re often treated as niche solutions—but in reality, they’re some of the most powerful (and most misunderstood) tools in OOG logistics.

So let’s talk about them

—not theoretically, not from a brochure, but from real operational experience.

In global shipping, standard 20’ and 40’ containers are still the default choice.

They’re simple, efficient, and ideal for true door-to-door movements.

But when cargo is too tall, too wide, or too heavy, the box stops being the solution.

In 2026, logistics is no longer just about moving fast or chasing the lowest rate.

It’s about flexibility, planning, and smart engineering decisions.

For oversized and irregular cargo, Flatrack and Open-Top containers are no longer “exceptions.”

They’re strategic tools—when used correctly.

Here’s a practical guide to help shippers navigate OOG cargo with clarity and confidence.

The “Middle-Ground” Solution for Oversized Cargo

When cargo exceeds standard dimensions, you usually have three options: breakbulk, flatrack, or open-top.

Flatracks and open-tops sit perfectly in the middle—more flexible than standard boxes, but far more accessible than chartering a vessel.

Flatrack Containers

Think of a flatrack as an ocean-going flatbed.

• Ideal for cargo that is too wide or too long
• Easy side or top loading
• Requires professional lashing and exposure management

Open-Top Containers

An open-top keeps the box walls but removes the roof.

• Best for over-height but stable cargo
• Crane-friendly loading
• Better side protection than flatracks

Part 1: The Core Comparison

The primary difference lies in structural containment, protection, and loading access.

Part 2: User Guide – Which One Do You Need?

Option A: Choose the Open-Top Container

Use this when your cargo is tall, heavy, or needs crane loading, but still fits within the standard width of a container.

• Best For: Heavy machinery, industrial parts, glass sheets, loose scrap, or equipment bodies that cannot fit through a standard container door,.
• Operational Advantage: You maintain the protection of steel walls. The removable canvas/tarpaulin is designed to keep rain out, though it is not a hermetic seal.
• Constraint: You must ensure the "bows" (roof supports) can be removed and that the door header (if removable) is handled correctly to facilitate loading.

Option B: Choose the Flatrack Container

Use this when your cargo creates a geometric challenge—specifically if it protrudes horizontally or has an irregular shape that prevents it from sitting inside a box.

• Best For: Steel beams, bundled pipes, boats, vehicles, or machinery that exceeds the width or length of the container base,.
• Operational Advantage: It allows for "out-of-gauge" (OOG) width. Additionally, Hapag-Lloyd notes that flatracks are designed to carry heavier and more concentrated loads than standard equipment, provided the weight is transferred to the bottom rails.
• Constraint: Because there are no walls, you are solely responsible for creating the "containment" via lashing. You must not stow over-width cargo within 30 cm (12 inches) of the corner posts, or the container cannot be loaded under deck.

Part 3: Operational & Safety Best Practices

Managing these containers requires "engineering" rather than just "shipping." Adhere to the following guidelines derived from the IMO Code of Safe Practice and carrier guidelines.

A. The Lashing Plan (Mandatory)

Unlike standard boxes where walls hold the cargo, you build the walls on a flatrack using lashing.

• Physics of Lashing: According to IMO standards, to prevent sliding, lashing angles should not be higher than 25°. To prevent tipping, lashing angles should be between 45° and 60°,.
• Friction: Metal-on-metal loading is dangerous. You must use dunnage (wood) or rubber mats between the cargo and the container floor to increase friction,.
• Material: Do not mix different lashing materials (e.g., wires and web lashings) on the same cargo in the same direction, as they have different elasticity and will not share the load equally.

B. Cost Management: "Lost Slots"

Carriers charge for the space your cargo blocks, not just the space it sits on.

• The Mechanism: If your Flatrack cargo protrudes 10cm over the side, it blocks the adjacent slot on the ship. You will be charged a "Lost Slot" fee for that unusable space,.
• Mitigation: Verify if slightly modifying the packaging (e.g., removing a skid or protective ear) can bring the cargo back "in-gauge" to avoid these massive surcharges.

C. Preparation and Documentation

• Measurement: Provide exact packed dimensions (Length x Width x Height) and Gross Weight. Do not use catalog dimensions; measure the final crate including skids and lifting lugs,.
• Lead Time: Demand for special equipment is rising (especially in manufacturing hubs like Vietnam). Book 2 to 3 weeks in advance to ensure the depot has the specific Flatrack or Open-Top available,.
• Lashing Certificate: Many ports and insurers now require a "Lashing Certificate" issued by a surveyor to verify that the cargo is secured according to IMO Annex 13 and other safety standards before the ship departs,.

Shipping OOG Is Engineering, Not Just Transport

OOG cargo doesn’t forgive shortcuts. Successful shipments follow three rules:

1. Choose the right equipment

Don’t overcomplicate—height issues often mean open-top; irregular shapes usually mean flatrack.

2. Take lashing seriously

Center of gravity, lifting points, and port compliance all matter. Poor preparation can stop your cargo at the terminal gate.

3. Plan routes and timing early

Special equipment isn’t unlimited. Book 2–3 weeks ahead and prioritize direct sailings to minimize handling risk.

The Trade-Offs You Should Know

Why not always choose breakbulk?

Because container vessels offer better frequency and cost efficiency. That said, flatracks and open-tops come with realities:

• Limited inland flexibility
• Exposure to weather
• Higher port handling costs

Knowing these upfront helps avoid surprises.

What’s Shaping the Market in 2026?

• Strong growth in Southeast Asia, driven by manufacturing exports
• More IoT-enabled monitoring for high-value equipment
• Sustainability gains through smarter container selection and fewer re-handles

Final Thought

Oversized cargo doesn’t have to mean oversized risk.

With the right container choice, proper lashing planning, and early coordination, Flatracks and Open-Tops can turn a complex OOG shipment into a controlled, predictable move.

• Open-Top Container: Like a convertible car. It has doors and windows to protect you, but the roof comes down so you can transport a tall item (like a surfboard) sticking out the top.
• Flatrack Container: Like a flatbed tow truck. There are no sides or roof; you can put anything on it regardless of how wide or weirdly shaped it is, but you must strap it down tightly because nothing else is holding it in place,.

Oversized cargo doesn’t automatically mean complex shipping—but it does require smarter planning.

Flatracks and open-tops offer a powerful middle-ground solution, as long as you treat the shipment like a project, not a transaction.

Plan early. Engineer the move.

That’s how OOG logistics stays under control.

Answer to the top questions:

1. When your cargo is too wide or too tall for a standard box, but still fits within the weight limits of container ship cranes. (Most 40' flat racks can handle up to around 40-45 tons) → Flat Rack
2. If the POD is near a major hub, then a flat rack will likely get there much faster than waiting for a specialized Breakbulk vessel.
3. A flat rack can be lifted directly from the ship onto a specialized truck chassis or a rail car. With breakbulk, you often have to coordinate specialized "heavy lift" equipment at the pier to move the item onto a trailer, which adds cost and time.

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