For Heavy Industrial Loads

When a multi-tonne coil rolls off a transport truck with a dent in its surface or a steel plate arrives at a mill bent instead of flat, the cost isn’t just replacement inventory—it’s production downtime, customer dissatisfaction, and the frustration of investigating where things went wrong. We’ve worked with steel producers, logistics operators, and heavy manufacturers long enough to know that the real solution starts before the load leaves the yard. It starts with dunnage construction that’s properly engineered for the weight, geometry, and journey ahead.

At Ferrier Industrial, we don’t view dunnage construction as a generic box-ticking exercise. It’s problem-solving built into the physical structure holding your cargo. Whether you’re protecting coils for intermodal transport, spacing timber bundles for long-haul routes, or cushioning precision components in transit, the construction of your dunnage shapes whether goods arrive intact. The materials matter—timber vs. composite, weight vs. durability. The design matters—how blocks are positioned, how rubber lining absorbs vibration, how height and spacing prevent load shift. And the lifecycle matters—whether your dunnage is single-use consumable or reusable protective infrastructure that justifies ongoing investment.

This article walks you through how to think about dunnage in your operation: what factors drive material choice, how design affects load protection, why durability and serviceability matter, and how to evaluate solutions that reduce damage and streamline transport workflows.

Context: Load Protection in ANZ Transport Operations

Australia and New Zealand’s heavy transport sector operates across demanding conditions: long interstate hauls, variable climate exposure, vibration through rough road networks, and mixed-mode logistics. Coils, sheets, tubes, and structural components travel these routes regularly, and protection quality determines whether goods arrive intact.

The cost of failure is straightforward. A dented coil or warped plate either gets remachined or scrapped. High-value components destined for aerospace or automotive often can’t be salvaged—the entire order may need re-running. Beyond direct cost, delayed shipments cascade through supply chains, damaging relationships and margins.

Dunnage addresses this by isolating loads from impact and vibration. Effective dunnage construction means material, dimensions, and design are matched to your specific load type and route. Standards and compliance also matter: export regulations may mandate fumigated timber, while customers often specify dunnage standards that dictate materials and dimensions. Your dunnage needs to fit those specifications cleanly.

How We Approach Dunnage: Materials, Design, and Durability

At Ferrier Industrial, our dunnage portfolio spans multiple material families because no single material works for every application.

LVL (Laminated Veneer Lumber) High-Friction Dunnage forms our core offering. We source eucalyptus-based LVL bonded with vulcanised rubber lining (typically 7 mm) to create blocks with exceptional friction properties. The rubber grips cargo without slipping even under vibration. We offer these in multiple cross-sections—50×100, 65×100, 75×75, 90×100 mm and custom sizes—each for specific load weights. Grades include packing (single-use), engineering (multi-use), and BWR waterproof (demanding export environments). LVL beats solid timber because it’s engineered to maintain consistency through moisture and temperature swings.

Composite Wood and Recycled Timber Blocks provide sustainable alternatives for lower-specification applications. These are ideal for single-journey exports or temporary spacing where durability is secondary to cost or environmental performance.

Vulcanised Rubber-Bonded Steel and Hardwood serves heavy-load, high-cycle uses: truck cradles, coil supports, chain protectors. Steel cores with vulcanised rubber bonded to load surfaces prevent metal-to-metal contact, absorb vibration, and provide friction to resist slipping.

Foam and Specialty Blocks handle precision or fragile goods, distributing point loads and cushioning impact. These are typically single-use and most suitable for smaller components or electronics.

Core Dunnage Construction Services and Material Options

• LVL high-friction blocks with vulcanised rubber lining in multiple cross-sections (50×100, 65×100, 75×75, 90×100 mm and custom sizes); BWR waterproof grade available for export; engineering grade for multi-use applications
• Composite wood and recycled timber spacing blocks; edge protectors and layering sheets for container efficiency and environmental sustainability
• Vulcanised rubber-bonded steel and hardwood cradles and supports; engineered for vibration damping and high-cycle durability in coil and sheet transport
• Foam and cushioning blocks for precision components; custom density and geometry to match load sensitivity and transport mode
• Heat-treated and fumigated timber options compliant with export phytosanitary standards

Dunnage Construction: From Design to Protection

Load geometry shapes dunnage design more than anything else. A coil resting on its bore requires different block positioning than a coil on its side. A flat sheet stack needs spacing for air circulation, while tubes need blocks positioned to prevent rolling. We map load types, sketch contact points, and identify where blocks must sit for maximum support.

Height and spacing are critical design factors. Too little clearance creates friction points causing surface marking during shifts. Too much clearance loses stability—coils or sheets can sag if spacing is too wide. Friction properties of dunnage materials affect spacing tolerances; high-friction rubber-lined blocks often use wider spacing because they prevent slipping.

Material choice flows from design. High-value alloys that can’t tolerate surface marking require vulcanised rubber-bonded blocks. Export shipments may need fumigated timber. Weight-sensitive applications (airline cargo) might require lightweight foam or composites.

We also consider the load’s journey. Local metropolitan hauls experience different vibration profiles than cross-country routes or ocean containers with multi-modal handling. Dunnage adequate for one journey type may be undersized for another.

Constructing Dunnage for Maximum Load Stability and Damage Prevention

Once design is settled, construction quality becomes the limiting factor. We focus on several key aspects:

Surface Preparation and Adhesion. When bonding vulcanised rubber to steel or hardwood, the adhesive bond is only as strong as the surface it’s applied to. We clean surfaces thoroughly, apply compatible priming agents, and cure rubber under controlled conditions. A poorly bonded rubber layer peels off under vibration, leaving you with bare metal and failed protection. We inspect every bonded assembly; failed adhesions get reworked before shipping.

Dimensional Consistency. Our LVL blocks are produced to tight tolerances (±2–3 mm). If blocks vary by 10 mm, your stacked coils end up uneven, leading to load shift and damage. We control this through production quality gates and verify dimensions before dispatch.

Edge Protection and Finishing. Sharp edges on dunnage blocks gouge cargo surfaces just as readily as unprotected loads damage blocks. We round or chamfer edges appropriately, sand surfaces smooth where contact with cargo is expected, and apply additional edge protection for extra-sensitive products.

Material-Specific Durability. LVL blocks need moisture management; we supply them in sealed packaging with desiccant where appropriate. Rubber-bonded blocks need UV protection when stored outdoors. Foam blocks can crush under their own weight if stacked too long. We communicate these care requirements clearly.

Integration: Dunnage Systems in Real-World Transport Workflows

Dunnage doesn’t exist in isolation. It sits within a broader system: load securing methods, container or vehicle selection, handling procedures, and inspection protocols.

When designing dunnage systems, we think about how your team will actually use them. Are blocks being manually positioned or mechanically placed? Do they need to survive one journey or fifty? Are you exporting, and if so, to which regions with phytosanitary requirements? Answers shape construction choices—more durable materials and protective finishes if blocks are reused and exposed to weather.

We also consider how dunnage integrates with other restraint methods. Dunnage is passive protection; it’s most effective paired with active restraint (straps, chain, or welded supports) that prevents load shifting. A coil on well-constructed dunnage but inadequately strapped can still roll during rough handling.

Compatibility with existing infrastructure also matters. Your warehouse may have forklifts rated for specific pallet sizes. Your containers may have interior dimensions limiting block height or placement. We factor these constraints into design so final systems integrate smoothly with existing operations.

Key Benefits and Procurement Considerations

Moving to better-constructed dunnage involves evaluating several factors beyond load protection.

Lifecycle value and repairability shape long-term cost. Single-use dunnage is sometimes necessary, but durable, reusable blocks often deliver better value. A well-constructed LVL block or rubber-bonded cradle serves for years if maintained properly. That extended service life spreads engineering investment across multiple journeys. Repairability matters too: if a block sustains minor damage (a crack, a rubber gouge), can it be repaired and returned to service, or must it be discarded? We design for repairability, and maintain documentation and spares for long-term use.

Supply continuity and standardisation reduce operational friction. If you standardise on a set of dunnage block sizes across your operations, you simplify inventory, reduce storage space, and make staff training easier. We work with clients to establish standard block families matched to common load types.

Compliance and documentation give confidence to shipping partners. If your dunnage meets customer-specified standards, documentation proves it. Export fumigation or heat-treatment certifications are straightforward to obtain and present. We maintain material traceability so you can demonstrate compliance.

Sustainability increasingly shapes procurement. Reusable systems reduce waste compared to single-use alternatives. LVL timber is sourced from sustainably managed forests and grows faster than solid hardwoods. We also work with recycled timber where appropriate. These factors appeal to procurement teams managing environmental commitments.

Benefits and Evaluation Criteria for Dunnage Solutions

• Load protection tailored to geometry and transport mode: Custom dunnage design matching your coil diameters, sheet dimensions, or component geometry with material and spacing optimised for local hauls vs. long-distance vs. export routes reduces damage rates and associated claims and rework
• Lifecycle value and serviceability: Durable, repairable dunnage blocks spread engineering investment across multiple journeys; standardised block families simplify inventory and training; documented material traceability and compliance certifications streamline procurement and reduce audit friction
• Supply continuity and design flexibility: Established partnerships with dunnage suppliers supporting JIT delivery, consignment stock for high-usage items, and custom dimension or material options as your transport needs evolve protect against supply disruptions and logistical constraints
• Environmental and cost efficiency: Reusable vs. single-use dunnage, sustainably sourced materials, and optimised block sizing to reduce per-shipment cost while meeting environmental and compliance commitments appeal to finance and ESG procurement objectives
• Integration with existing infrastructure: Dunnage systems designed around your warehouse footprints, forklift reach, container interior dimensions, and handling procedures reduce operational friction and hidden costs associated with incompatible systems

How We Design and Build Dunnage Solutions at Ferrier Industrial

When you come to us with a dunnage construction challenge, we begin with specifics. What’s the load type and weight range? What critical surfaces mustn’t be damaged? What’s the transport route and environment? Are you exporting? Do you have existing standards or customer requirements we need to meet?

From there, we move into collaborative design. We sketch load positioning, mark dunnage block locations, and identify contact points. We discuss material options and trade-offs: durability vs. cost, weight vs. protection, reusability vs. single-use convenience. We often prototype and test under conditions matching your transport reality.

Once design is locked in, we move to sampling and pilot trials. You receive a small batch with your loads and run them through your actual pipeline. We collect feedback: Are blocks staying in position? Are loads arriving undamaged? Is handling straightforward? Are there storage issues?

Based on pilot results, we refine if needed, then scale production. We establish supply continuity—typically JIT delivery or consignment stock. We provide documentation: drawings, material specs, compliance certifications, and care instructions.

From our Auckland and NSW facilities, we maintain ongoing support. If your needs change (new products, route changes, volume growth), we adjust designs, source additional materials, or arrange repairs.

Practical Implementation: Specifying and Deploying Dunnage

Starting a dunnage review is straightforward. Document your current loads in detail: sketch load profiles and dimensions, note material types, and record where damage typically occurs. If you’re not currently using dunnage, identify the damage patterns you’re experiencing without it.

Next, clarify constraints and requirements. What transport modes are involved? How many journeys must a block survive—one, ten, fifty? Are you exporting, and if so, to which regions? Do you have customer-specified standards, or is this your choice? What’s your budget tolerance for dunnage—cost-per-use, or total investment in reusable infrastructure?

Then evaluate options. Talk to prospective suppliers about material families, design approaches, and lead times. Request samples and specifications. Discuss serviceability: can blocks be repaired? How are spares managed? Can designs be modified if needs change?

Finally, plan a structured trial. Identify a representative shipment across your typical routes. Arrange dunnage from a supplier. Document baseline damage rates, then run the trial. Track whether damage reduces, whether handling is smooth, and whether any operational friction emerges.

Practical Dunnage Implementation Steps

• Load documentation and damage analysis: Photograph and sketch your typical load geometries, note material types and weight ranges, map current damage patterns (location, severity, root causes), and quantify damage rates if data exists so dunnage design targets the right risk areas
• Specification and design collaboration: Discuss transport modes, export requirements, customer dunnage standards, reuse vs. single-use tolerance, and budget constraints with prospective suppliers; request material samples and specifications; validate design concepts against your actual warehouse and transport equipment (forklift clearance, container interior dimensions, handling procedures)
• Pilot trial and refinement: Run dunnage through one or more representative shipments capturing baseline and trial performance; collect feedback from warehouse and transport staff on handling ease, storage, and any operational friction; track damage rates, cost per use, and time impacts to evaluate whether scaling is justified
• Supply agreements and support planning: Establish agreements around material sourcing, lead times (JIT vs. batch delivery), consignment stock if applicable, spares management and repair support, and change management (how modifications to block sizes or materials are handled as transport needs evolve)

Conclusion: Dunnage Construction as Operational Infrastructure

Dunnage is one of those things that works best when it’s invisible—loads arrive undamaged, and nobody thinks much about the blocks underneath. But that invisible reliability is only possible when dunnage construction is thoughtful, material choices are matched to loads, designs are validated, and supply continuity is managed.

We at Ferrier Industrial have spent decades designing and building dunnage solutions for steel mills, logistics operators, manufacturers, and exporters across ANZ. What we’ve learned is that the best dunnage outcomes come from treating construction as a serious engineering problem, not a commodity task. It means understanding your specific loads, your transport environment, your constraints, and your tolerance for risk. It means designing accordingly, validating through pilots, and maintaining the infrastructure with the same rigour you’d apply to any other asset.

If you’re reviewing your dunnage systems—whether because you’re experiencing damage you want to prevent, or because you’re scaling operations and want to ensure protection across larger volumes—we’d welcome a conversation. Share your load details, your transport profile, and your constraints. We’ll sketch out some material and design options, discuss what a pilot might look like, and outline how we’d support ongoing supply and refinement. Reach out with your requirements, and we’ll put together a proposal and samples for evaluation.