The Challenges Faced& Overcame
Transporting a 40,000+ kg single-crate unit introduced several operational and logistical challenges:
Carrier & Terminal Limitations
- Not all terminals and carriers are equipped to handle cargo of this weight on flatrack equipment.
- MGT Terminal was unable to accommodate the load.
- Termont Terminal had the lifting capability but required the cargo to move as breakbulk due to carrier restrictions.
Flatrack Equipment Constraints
A standard flatrack was insufficient. During inspection, it was determined that a specialized flatrack with a 54-ton payload capacity was required—equipment that is not always readily available.
Weight Discrepancy Risk
On loading day, the cargo weight was recorded at 41,731 kg, exceeding initial estimates. This posed a serious risk of non-compliance with equipment payload limits.
Complex Handling Requirements
From crane loading at origin to securing the cargo for ocean transport, every step required precise coordination, specialized equipment, and adherence to strict safety standards.
how falconResponded
Falcon managed the shipment from origin to export readiness through a carefully coordinated, multi-step process:
Crane Loading at Origin (IVYS Facility)
We arranged a specialized crane operation to safely lift and load the PSA unit onto the transport truck. Every movement was planned to ensure stability and safety given the cargo’s extreme weight.
Transport to TRT Warehouse (New York)
The shipment was handled by Bellemare and delivered to the TRT warehouse, where it was staged for export preparation.
Securing Specialized Flatrack Equipment
After identifying equipment requirements during NCB inspection, our team coordinated closely with the NYC terminal to source a 54-ton capacity flatrack, even though it required adjusting the sailing schedule.
Carrier Solution via Hapag-Lloyd
Through persistent coordination, Falcon secured approval from Hapag-Lloyd’s special cargo team, enabling the shipment to move on flatrack instead of breakbulk—providing a more efficient and cost-effective solution.
Weight Verification & Compliance
To address the weight discrepancy, we arranged for certified scale verification, ensuring compliance and allowing the shipment to proceed without delays.
Lashing & NCB Approval
The cargo was expertly secured using proper lashing techniques and successfully passed NCB inspection, meeting all ocean carrier safety standards.
Why falconWas Chosen
The client selected Falcon based on several key factors:
- Proven expertise in heavy-lift and oversized cargo
- Strong relationships with ocean carriers and terminals
- Ability to provide end-to-end project coordination
- Reputation for solving complex logistics challenges
Falcon’s consultative approach and ability to anticipate potential obstacles gave the client confidence that their shipment would be handled with care and precision.
TheResults
Despite multiple challenges, Falcon delivered a successful outcome:
- Secured a carrier solution for a highly restricted cargo profile
- Coordinated specialized equipment with limited availability
- Ensured full compliance with safety and inspection standards
- Avoided costly delays through proactive problem-solving
- Successfully prepared the PSA unit for ocean export
This project demonstrates Falcon’s ability to manage complex, high-stakes logistics operations involving heavy and oversized cargo. From navigating terminal restrictions to resolving last-minute weight discrepancies, our team ensured every detail was handled with precision.
40K kgs, 0 damage, 0 delays