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Pillar guide15 min readUpdated 15 avril 2026

Project cargo: heavy lift, out-of-gauge and turnkey logistics

From lead phase to site hand-over – how logistics providers plan, coordinate and ship complex project cargo safely and economically.

Project cargo is logistics at its most demanding: wind components, transformers, turbine parts, plant loads to 800 tons, offshore platforms, refinery columns. Mistakes delay billion-dollar projects. This pillar explains how project cargo is planned and executed professionally – from RFQ to site hand-over.

Typical weight range
50–800+ tons per piece
Typical OOG dimensions
Width > 2.5 m, height > 2.9 m, length > 12 m
Project lead time
6–24 months from planning to delivery
Logistics share of project cost
5–25% depending on sector
Permit lead times DE
4–12 weeks per state
Global heavy-lift fleet
≈ 280 vessels (2025)

01What sets project cargo apart from general cargo

Project cargo is defined by single-piece weight, dimensions or complexity that make standard transport impossible. Core traits:

  • Heavy lift: > 50 t single piece, specialised vessels with 350–3,000 t SWL cranes.
  • OOG: Dimensions exceed standard container, need flatrack, open top, breakbulk or Ro/Ro.
  • Multimodal turnkey: factory to site incl. pre/on-carriage, port, barge, SPMT.
  • PM intensity: tightly sequenced with EPC milestones; small delays cascade.

02Planning and route survey

The backbone is the route survey. It tests feasibility end-to-end: factory gate, road route, bridge loads, port cranes, sea route, destination country, last-100 km. Lead 4–12 weeks.

03Transport means and concepts

Specialised assets:

  • Heavy-lift freighters: With on-board cranes (BigLift, COSCO HL, UHL, AAL, Sal). Tandem lifts double capacity.
  • Breakbulk liners: Scheduled for over-panamax cargo.
  • Ro/Ro: Rollable loads on MAFI trailers.
  • Flatrack / Open-top: Medium OOG up to 40 t and 12 m.
  • Barge: Rhine, Danube, Meuse for bridge and water-level constraints.
  • SPMT: Self-propelled modular transport for 50–1,500 t.

04Cargo securing and lashing

Securing is safety-critical: IMO CSS Code, IMO Cargo Securing Manual, DIN EN 12195 / VDI 2700 for road, lashing calculation considering wind/wave/inertia, independent marine surveyor as insurance condition precedent.

05Permits and public-authority coordination

Road permits per country:

  • DE: § 29 / § 46 StVO, 4–8 weeks lead.
  • CH: Astra derogation.
  • AT: § 101 StVO.
  • EU cross-border: per state, coordinated via partner network.

Bridge statics, road closures, police escort, signal phasing – early engagement avoids show-stoppers.

06Insurance, liability, risk allocation

Project cargo runs on ICC A (all risks), DIC/DIL top-ups, marine warranty surveyor, heavy-lift clauses, carrier P&I. Risk allocation via Incoterms and bespoke clauses. A project risk register (likelihood, impact, mitigation, owner) is essential.

Frequently asked questions

What is the difference between heavy lift and breakbulk?
Heavy lift = single piece > ~50 t requiring specialised lifting. Breakbulk = non-container general cargo of any weight. All heavy lift is breakbulk; not all breakbulk is heavy lift.
How long does a complex wind-power shipment take?
A complete wind-farm delivery (towers, nacelle, blades, transformer) takes 3–9 months from factory to site, gated by production, vessel charter (often booked 12 months ahead), port slots, road permits and erection sequence.
What is a COA?
A Contract of Affreightment commits a carrier to ship a volume or voyage count over 6 months to 5 years. Common for recurring project series.
Does every heavy lift need a marine surveyor?
Practically yes – insurance from USD 2m upwards typically requires a Marine Warranty Surveyor (MWS) to oversee loading, securing and discharge.
How to cost a project-cargo RFQ?
Cost blocks: pre-haul, port handling, sea leg (charter/liner), destination port, on-carriage with permits and escort, ICC A insurance, PM and survey, 5–15% contingency. Transparent quotation is industry best practice and increasingly demanded.

Topics

project cargoheavy liftOOGbreakbulkSPMTheavy transportroute surveymarine warranty surveyorwind logisticsRo/Ro

Further resources

Sea freight category
For forwarders
Road category