Types of Dunnage

Selecting the Right Material for Cargo Stability

Cargo damage during transport doesn’t announce itself with fanfare. It happens quietly — a pallet shifts slightly during truck braking, a coil stack settles unevenly as temperature swings, moisture creeps into a shipment during a humid coastal journey. By the time the damage is discovered, it’s too late. The dunnage that was supposed to protect your load has either failed to do its job or wasn’t right for the job in the first place.

We work with logistics teams, manufacturing plants, and distribution centres across Australia and New Zealand who’ve learned this lesson the hard way. At Ferrier Industrial, one of the questions we hear most often is: “What types of dunnage should we be using?” It’s a deceptively simple question with a complex answer — because the right dunnage depends on your cargo type, load profile, transit environment, and how many times you plan to reuse it. Get the selection wrong, and you’re either over-specifying (wasting money) or under-protecting (risking costly claims). Get it right, and your cargo arrives intact, your handling costs stabilise, and your operations run predictably.

This article walks through the main categories of dunnage in use today, explains the material properties and operational trade-offs that matter, and shows you how to match dunnage type to your specific challenges. Whether you’re shipping coils, minerals, manufactured goods, or perishables, understanding your dunnage options gives you control over protection and cost.

Why Dunnage Choice Matters More Than You Might Think

Dunnage is the protective infrastructure that sits between your cargo and everything that could damage it: friction during acceleration and braking, vibration from road imperfections, crushing force from stacking, moisture and temperature swings, and contact with handling equipment.

A poorly chosen dunnage can multiply your problems. Soft foam blocks might protect against impact but offer almost no restraint if your load shifts sideways during a hard turn. Untreated hardwood can swell and warp in humid environments, compromising the dimensional stability your load depends on. Overly rigid dunnage can concentrate forces instead of distributing them, potentially cracking brittle cargo rather than protecting it.

On the flip side, the right dunnage — matched to your cargo weight, geometry, transit route, and environment — becomes invisible. Your load arrives undamaged. Handling time stays predictable. Claims and returns drop. Customers receive goods in the condition they expect. For procurement teams evaluating packaging systems, dunnage selection is where engineering, cost control, and risk management intersect.

The challenge is that there’s no universal dunnage solution. A high-friction LVL block that’s perfect for restraining coils on an exposed truck deck might be overkill — and wasteful — for a containerised, climate-controlled shipment of electronics. A foam block that cushions glassware beautifully adds weight and cost if you’re shipping heavy castings that need grip, not softness.

Understanding the types of dunnage available, the material properties that drive their performance, and the cargo scenarios where each excels is the foundation of smart cargo protection.

Core Categories of Dunnage and Their Operating Principles

Modern cargo protection relies on a toolbox of dunnage types, each engineered for different challenges. We source, design, and deploy these across multiple industries, and the principles behind each type are worth understanding clearly.

LVL (Laminated Veneer Lumber) dunnage stands out as the flagship high-friction option in the ANZ market. Engineered from sustainably grown softwood veneers bonded with waterproof adhesive, LVL is inherently stable — it resists moisture-induced warping that plagues solid timber in humid climates. Crucially, we bond a vulcanised rubber lining to the contact surface, which creates exceptional grip. This combination of dimensional stability and high friction makes LVL dunnage the preferred choice for load restraint, particularly where coils, pipes, or castings must be held in place during dynamic transport.

Hardwood dunnage — typically eucalyptus or similar species sourced locally in ANZ — offers brute durability. It’s denser, harder, and more resistant to crushing than LVL. Hardwood dunnage excels where cargo will experience rough handling, repeated stacking cycles, or heavy point loads. However, hardwood is vulnerable to moisture and temperature shifts, which can cause swelling, warping, and eventual splitting. If you’re shipping through tropical ports or storing dunnage in open-air yards, hardwood can become unpredictable.

Foam and composite blocks serve a different purpose entirely. These are protective cushions, not load restraints. Foam works by absorbing impact energy, distributing crushing force over a wider area, and conforming slightly to cargo geometry. It’s ideal for protecting delicate goods — glassware, ceramics, precision electronics — where friction and rigid support would cause damage. Foam is lightweight, which helps manage freight costs, and it’s easy to cut or shape for custom applications. The trade-off: foam offers almost no horizontal stability or restraint, so it’s unsuitable for cargo that needs to be locked in place during transport.

Specialty blocks and fabricated dunnage cover a wider range: rubber-faced blocks for mixed-mode protection, extruded plastic edge protectors for coil edges, steel frames for custom load geometries, and bespoke fabrications for unusual cargo profiles. We design these on a project basis, integrating them with your specific cargo, handling equipment, and container dimensions.

Coil dunnage and storage blocks are engineered specifically for coil transportation and storage. Vertical coil restraint corners, horizontal restraint equipment, and purpose-built coil cradles all fall under this category. These are often customised to your coil size, weight, and handling method.

Dunnage airbags — pressurised bags that fill void spaces in containers — serve as restraint and void fillers. They’re particularly useful in consolidation operations where you’re mixing different cargo sizes and need to prevent load shift without adding rigid structure.

VCI (Vapour Corrosion Inhibitor) packaging isn’t dunnage in the traditional sense, but it’s often deployed alongside dunnage to protect metallic cargo from corrosion during transit and storage.

Each type has a specific job. Understanding which job you’re trying to accomplish is where intelligent dunnage selection begins.

Matching Dunnage Type to Cargo and Transport Scenario

Cargo type is the primary driver of dunnage choice. Here’s how we think through the decision with our clients:

Coils, pipes, and cylindrical cargo demand restraint above all else. These loads are inherently unstable — cylindrical geometry means minimal contact surface, and they can roll or shift with minimal provocation. LVL dunnage with high-friction rubber lining is the standard choice here. The rubber provides grip; the LVL provides dimensional stability. We often combine this with engineered coil corners (vertical or horizontal restraint), additional ratchet straps, and sometimes dunnage airbags to fill voids and prevent secondary movement. The goal is absolute lock-down: the coil shouldn’t move a millimetre during transport.

Castings, machinery parts, and heavy rigid cargo often favour hardwood or LVL dunnage, depending on handling intensity and environment. If the cargo is rough-handling and will experience stacking in outdoor yards, hardwood’s durability might justify its weight penalty. If the cargo will move through containerised, climate-controlled logistics networks, LVL’s stability and lower weight become more attractive. The deciding question is usually: how many handling cycles will this cargo experience, and will moisture exposure be an issue?

Glassware, ceramics, and fragile goods shift the equation entirely. Here, foam or composite protective blocks are standard. The priority isn’t restraint; it’s absorbing impact and distributing point loads. A foam block under each corner of a glass shipment will prevent shattering from drop impacts far more effectively than a hardwood block would. Foam is also light, which keeps freight surcharges down.

Perishables and temperature-sensitive cargo introduce environmental considerations. Standard wood dunnage can absorb moisture, potentially compromising your temperature control or creating mould risk. Some teams specify treated or sealed dunnage, or shift to plastic or composite blocks that won’t swell or absorb. The investment in the right dunnage material often pays for itself by preventing a single spoiled shipment.

Minerals and construction materials — often heavy, rough, and prone to moisture exposure — typically use hardwood dunnage or engineered plastic blocks. Cost matters here; these shipments are often high-volume and margin-sensitive. We help clients evaluate cost-per-use and durability trade-offs to identify the sweet spot.

The transit environment matters equally. A shipment moving by dedicated truck from a manufacturing plant to a nearby distribution centre faces different risks than an export container moving through tropical ports and humid storage yards. Climate, handling intensity, stacking pressure, and vibration exposure all factor into which dunnage type will remain stable and functional.

Performance Durability and Lifecycle Thinking

One of the under-appreciated aspects of dunnage selection is lifecycle cost. A cheaper foam block might seem attractive on a per-unit basis, but if it crushes after a single use, your actual cost-per-cycle is terrible. Conversely, heavy hardwood dunnage might last indefinitely, but the freight cost to move it might outweigh the durability benefit for low-reuse scenarios.

We encourage clients to think in terms of cycles: How many times will this dunnage be reused before it’s eventually recycled or disposed of? A courier operation moving parcels might reuse dunnage dozens of times per year. A heavy industry shipper moving coils might use dunnage three or four times before it’s damaged or worn. Export operations might use dunnage once, then recycle it at destination.

LVL dunnage typically delivers excellent value for multi-cycle use. The engineered material resists warping, the rubber lining doesn’t degrade quickly, and it can be refurbished — rubber replaced, surface sanded — if it becomes worn. Hardwood dunnage often lasts longer but can deteriorate unpredictably in humid environments. Foam is economical for single-use but degrades quickly under reuse.

We’ve also seen teams underestimate storage and maintenance costs. Dunnage that’s stored incorrectly — left exposed to weather, stacked improperly, or allowed to sit in contaminated conditions — deteriorates faster than expected. Specifying dunnage that’s appropriate to your storage environment (covered vs. outdoor, climate-controlled vs. uncontrolled) is part of smart lifecycle planning.

Integrating Dunnage with Broader Cargo Protection Systems

Dunnage doesn’t work in isolation. It’s one component of a cargo protection system that also includes pallets, straps, restraint mats, airbags, and sometimes liners or edge protection.

For example, a coil shipment might sit on an engineered pallet, be restrained with vertical coil corner blocks (LVL with rubber), have ratchet straps running through the load, and have dunnage airbags filling voids between the coil and container walls. Each component serves a specific function, but they only deliver reliable protection when they’re coordinated.

We’ve worked with teams who specified excellent dunnage but poor straps, or great restraint corners but inadequate pallet stability. The weak link in the chain is what fails. During our discovery process with new clients, we always review the complete system: pallet type and condition, dunnage selection, restraint equipment, and any liners or edge protection. If something is mismatched, we’ll flag it.

One practical consideration: the friction properties of your dunnage need to work with your restraint system. If you’re using high-friction LVL dunnage but low-grip straps, the straps might slip under load. Conversely, if your dunnage is slick (untreated hardwood or poorly maintained surfaces), even quality straps might not hold effectively. Matching materials and surface properties across the system eliminates these surprises.

Similarly, dunnage dimensions need to fit your cargo geometry, your pallet footprint, and your container dimensions. A dunnage block that’s too tall might prevent proper stacking. One that’s too short might leave gaps where cargo can shift. Getting the dimensions right — or specifying custom sizes — is a critical detail that’s easy to overlook.

Key Considerations for Dunnage Selection and Supply

When you’re evaluating dunnage options for your operation, these factors typically matter most:

  • Cargo type and weight profile — delicate goods, rough goods, heavy loads, and mixed cargo all require different dunnage approaches. Be specific about what you’re shipping and how it will be handled. Don’t assume a universal solution will work across all cargo types.
  • Reuse cycles and lifecycle cost — count how many times you expect to use dunnage before it’s retired. Multi-cycle scenarios favour durable materials like LVL or hardwood. Single-use shipments might justify lighter, cheaper options even if durability is lower.
  • Storage and environmental conditions — dunnage stored outdoors or in humid, uncontrolled spaces will behave differently than dunnage in climate-controlled warehouses. Specify materials that can tolerate your actual storage environment.
  • Restraint system compatibility — ensure your dunnage surfaces, friction properties, and dimensions work effectively with your straps, mats, and other restraint equipment. Mismatches create gaps in your protection.
  • Supply continuity and lead time — if you’re specifying custom dimensions or specialised materials, confirm lead times with your supplier. Don’t get caught short during peak seasons.
  • Regulatory and compliance requirements — some destinations or industries have specific dunnage material requirements. Pharmaceutical shipments, for example, sometimes prohibit certain foam types or treatments.
  • Sustainability and end-of-life pathways — consider whether your dunnage can be recycled, composted, or recovered for energy after use. This aligns with many organisations’ environmental commitments and sometimes reduces disposal costs.

How We Guide Dunnage Selection at Ferrier Industrial

Our approach to dunnage starts with understanding your cargo and constraints, not pushing a particular product.

We ask: What are you shipping? What does it weigh? How is it handled — manually, with equipment, both? What environments will it encounter — climate-controlled containers, exposed truck decks, humid storage? How many times will the dunnage be used? What’s your primary concern — damage prevention, cost control, supply reliability, sustainability, or a mix?

From those answers, we map out options. For a coil shipper concerned about damage and reusing dunnage across multiple cycles, we might recommend LVL dunnage with engineered coil corners, combined with a pallet assessment and a simple pilot to confirm the system works. For a fragile goods shipper focused on single-use protection, we might spec foam blocks and recommend a container liner to reduce moisture risk.

We maintain stock of standard LVL sizes and specifications at our NSW and Auckland facilities, which means faster turnaround than waiting for custom orders. If you need non-standard sizes or materials, we design and prototype with you — samples, drawings, fit-checks — before committing to volume production. We also coordinate dunnage sourcing with your broader packaging system: pallets, restraint equipment, liners, and edge protection all work together.

Our team has practical experience across postal and courier operations, steel and heavy industry, mining, construction, agriculture, and food logistics. We’ve seen how dunnage performs across these sectors and can draw on that experience to help you avoid common pitfalls.

We’re also conscious of supply continuity. If your dunnage supplier is stretched or unable to meet peak-season demand, we can often fill gaps. JIT delivery and consignment stock options help you manage inventory costs without running out.

Practical Framework for Specifying and Deploying Dunnage

If you’re reviewing your dunnage strategy or rolling out a new approach, here’s a practical process:

  • Audit your current cargo handling and damage rates — identify which cargo types experience the most damage and which routes or handling steps are most problematic. This data tells you where better dunnage will deliver the biggest impact.
  • Map cargo types to dunnage requirements — create a simple matrix: cargo type, weight, geometry, handling intensity, environment exposure, reuse cycles. Then note the dunnage properties that matter for each: friction, cushioning, dimensional stability, weight, cost.
  • Evaluate material options against your criteria — for each cargo type, list the candidate dunnage materials (LVL, hardwood, foam, composite, custom) and score them against your criteria. Often, one or two options will emerge as clear winners for each scenario.
  • Conduct a pilot with candidate dunnage — don’t specify large volumes based on theory alone. Source samples of your shortlisted dunnage types, integrate them into your actual loading, transport, and storage process, and run them through a full cycle. Measure damage rates, handling time, storage behaviour, and cost-in-use.
  • Confirm compatibility with your restraint and pallet system — ensure your chosen dunnage works seamlessly with your existing straps, mats, pallets, and containers. If there’s a mismatch, address it before scaling up.
  • Document your dunnage specifications and sourcing details — maintain a clear record of dunnage type, dimensions, material properties, supplier contact, lead times, and cost. This becomes your reference for future orders and troubleshooting.
  • Monitor performance and adjust as needed — after rollout, gather feedback from handling teams. If damage rates remain higher than expected or costs drift upward, revisit your dunnage choice. Continuous refinement is normal.

Dunnage as a System, Not an Afterthought

The best dunnage isn’t the most expensive or the most specialised. It’s the dunnage that’s matched intelligently to your cargo, integrated seamlessly with your other protective systems, and sourced reliably so you never run short.

At Ferrier Industrial, we’ve built our reputation on exactly this kind of practical, systems-level thinking. We don’t hand you a catalogue and wish you luck. We engage with your operational reality, understand your constraints and priorities, and help you choose types of dunnage that work for your business.

If you’re shipping goods at scale — whether it’s coils, minerals, fragile goods, perishables, or anything else — the right dunnage strategy saves money, reduces damage, and simplifies operations. We’re here to help you get there.

If you’re evaluating your current dunnage approach or planning a refresh, we’d welcome a conversation. Share your cargo profiles, volumes, transit routes, and current challenges with our team, and we’ll put together some practical options — including material samples, cost comparisons, and recommendations for integration with your broader packaging system. We can also organise a site visit or simple pilot if that’s useful.

Reliable cargo protection starts with dunnage that does its job. Let’s make sure yours does.