Business air cargo
Heavy domestic air cargo: plan each crate, not just the total
By PORTADOR editorial team · Published
For a 200–1,000 kg domestic air cargo enquiry, submit a separate record for every packed crate: gross weight, complete outside dimensions, orientation, base and lifting access, plus stacking limits. Confirm how each unit will be accepted and handled on the proposed aircraft and at both ends. A shipment total or a suitable-looking flight alone does not establish acceptance.
Separate shipment weight from individual-piece acceptance
A 600 kg consignment might contain six separate packages or one indivisible machine. Those are different handling problems. Record each complete packed unit, including its crate and base, rather than dividing the shipment total by the package count. Identify the heaviest piece and any item that cannot be split or repacked.
Air India's published fleet information distinguishes aircraft cargo-door dimensions, loading configurations and ULD specifications. That illustrates why a general aircraft cargo-capacity figure cannot establish acceptance for a particular crate. Ask for assessment against the aircraft and handling arrangement proposed for your movement; do not transfer a published specification to another aircraft or route.
Measure the complete outside shape
Measure the finished crate at its longest outside extents. Include the pallet or skids, protective covers, external braces, handles and protruding fittings. A drawing of the machine inside the crate is insufficient. Give length, width and height in centimetres, gross weight in kilograms, and clear photographs from several sides.
State whether the unit must remain upright and whether any tilt or rotation is permitted by its packing design. Do not assume that a crate can be turned to pass through an opening. Share an irregular profile or an offset centre of gravity with the operations team and obtain packing or lifting instructions from the equipment supplier where needed.
Show how the base can be handled
A protective crate still needs a practical way to be moved. Describe its base, skids and accessible lifting points. Where forklift handling is proposed, show the entry sides and clearances so the handling team can assess them. A pallet, lifting eye or forklift pocket is not by itself approval for every handling method.
Before sealing the packing design, ask the supplier and operations team to agree suitable handling options. Confirm who provides the required equipment and competent personnel at collection and delivery. Avoid leaving the receiver to improvise unloading after the cargo arrives.
Declare stacking limits before space is assessed
Tell the team explicitly when a crate is non-stackable or cannot carry weight on top. If stacking is permitted, obtain the packing supplier's stated top-load limit and conditions; do not estimate them from how strong the lid looks. A limit applying to an evenly distributed load is not permission to place a concentrated load anywhere on the crate.
Keep these instructions consistent on the packing list, photographs and package markings. Non-stackable cargo or an unknown top-load rating needs a specific space and acceptance assessment. Do not remove a restriction merely to make an indicative plan fit.
A three-crate example: 535 kg still needs three decisions
Consider this illustrative packing list. The weights are gross packed weights and the dimensions include each base. These illustrative measurements are not airline acceptance limits or a confirmed transport plan.
- Crate A: 160 × 100 × 95 cm; 260 kg; must remain upright; non-stackable; base access shown in photographs.
- Crate B: 120 × 100 × 85 cm; 180 kg; packing supplier declares a 50 kg evenly distributed top-load limit, subject to handling assessment.
- Crate C: 100 × 80 × 75 cm; 95 kg; top-load rating not supplied, so stacking must not be assumed.
Resolve the example's handling gaps before collection
The total is 260 + 180 + 95 = 535 kg. Crate A is both the heaviest unit and the longest. Its individual geometry, orientation and gross weight need assessment; the total cannot answer those questions. Crate B's stated 50 kg top-load limit would not justify placing either of the other example crates above it.
Crate C still needs a stacking declaration. If the destination has no suitable unloading equipment, identify an agreed alternative before confirming collection. Repacking or dividing a unit may be an option only if the equipment supplier approves it; request a fresh assessment using the revised packed details.
Make the receiving site part of the acceptance plan
Check vehicle access, gate and doorway clearances, the unloading position and the route to the receiving area at both ends. Confirm appointments, equipment availability and the person responsible for unloading. These are practical planning checks to agree with the relevant teams, rather than universal airline rules.
Describe the contents of every crate, including any batteries, liquids or other items requiring acceptance review. Send PORTADOR the per-crate list, photographs, handling declarations and required delivery time. Use the calculator separately for weight preparation. A pickup request, quotation acceptance and confirmed collection remain distinct; aircraft suitability, capacity and the complete handling plan require shipment-specific confirmation.