Breakbulk Damage Prevention: Lashing, Dunnage and Storage

Breakbulk cargo gets damaged in a small number of predictable ways. A piece shifts at sea because the lashing was too light. Steel rusts because it sat on wet ground. A crate gets crushed because something heavier was stowed on top of it. Packing, lashing and storage prevent most of this, and all three are decided before the cargo reaches the ship.

Why breakbulk is more exposed than containers

A container protects its contents from weather and from other cargo. Breakbulk has no box. Each piece is lifted on its own, stowed in a hold or on deck next to other cargo, and handled again at discharge. Every lift and every move is a chance for damage, and on deck the cargo is also exposed to sea spray and rain. If your cargo could fit on a flat rack or in an open-top container instead, our guide on flat rack, open top or breakbulk compares the options.

Packing: the first layer

• Match the packing to the voyage. A short Gulf voyage under deck needs less than a long ocean passage on deck. Tell the packer where the cargo will stow if you know.
• Corrosion protection for steel and machinery. VCI wrapping, desiccants inside crates and sealed covers on exposed machined surfaces. Salt air does the damage, not just rain.
• Crates and skids built for lifting. Skids should take forklift tines, and crates should be strong enough to be lifted by slings at marked points without bending.
• Clear marking. Lifting points, centre of gravity, "this way up", and the gross weight on at least two sides. Stevedores work fast. If the marks aren't obvious, they guess.

Lashing: keeping the cargo still at sea

Most sea damage happens when cargo moves. Ships roll and pitch, and a heavy piece that shifts a few centimetres can break its own lashings and hit its neighbours.

• Lashing is calculated for the cargo's weight and the forces expected on that ship and route. Carriers follow the vessel's cargo securing manual, which is based on IMO guidance. For heavy or unusual pieces, ask for the lashing calculation.
• Use the lashing points the manufacturer designed. Lashing round a weak part of a machine can damage it as the ship moves.
• Chains, wire and webbing each have a place. Webbing is gentler on painted surfaces but has lower strength. Chains and wire need edge protection where they touch the cargo.
• On longer voyages the crew should check and re-tension lashings. It is reasonable to ask the carrier whether this is done.

Dunnage: the part people skip

Dunnage is the timber, rubber or other material placed under and between cargo pieces. It spreads the load across the deck or tank top, stops steel touching steel, lifts cargo clear of any water in the hold, and adds friction so pieces are less likely to slide. Wooden dunnage used on international voyages must meet ISPM 15 treatment rules, or it can be rejected at the destination. Cheap or wet dunnage causes as much damage as no dunnage at all.

Lifting and handling at the port

• Lift only from marked points, with slings and spreader bars rated for the weight.
• Check the crane's capacity at the working radius, not just its maximum capacity.
• Avoid lifting in strong wind. In the Gulf, summer shamal winds and sudden squalls are the usual reason a lift gets stopped.
• Note any damage on the tally sheet before the cargo leaves the ship or the quay. A damage claim without that record is hard to win.

Storage before loading and after discharge

Breakbulk often waits days or weeks at the port or in a yard. Store it on dunnage or bearers, never directly on sand or wet ground, and cover steel and machinery with breathable covers that don't trap condensation. Gulf summer heat and humidity cause condensation inside wrapped cargo overnight, so ventilation matters as much as the cover. Keep heavy and light pieces apart so nothing gets stacked by accident.

Records and insurance

Photos at the factory, at loading and at discharge give you a timeline if something goes wrong. Check whether your cargo policy covers on-deck stowage, because many don't by default. For a full look at the documents and port steps, see breakbulk documents and the port process in the UAE.

Anil Darya plans packing, lashing and storage as part of our breakbulk and project cargo shipping through Jebel Ali. Send us the dimensions, weights and photos of your cargo through the rate inquiry form or at info@anildarya.co, and we will tell you what packing and securing the move needs.