Less-than-truckload (LTL) shipping is a common solution for metal distributors, manufacturers, and fabricators who need to transport smaller shipments without paying for a full truckload. While LTL shipping offers cost savings and flexibility, it also presents unique challenges when transporting metals due to their weight, size, and susceptibility to damage.
In this blog, we’ll break down the key challenges of LTL shipping in the metals industry and provide insights on how to navigate them effectively.
What is LTL Shipping?
LTL shipping is used when a shipment doesn’t require a full truckload, allowing multiple businesses to share space on a single truck. While this method reduces costs, it also means shipments are handled multiple times at various terminals before reaching their destination.
Why LTL Shipping is Common in the Metals Industry
✔ Helps companies ship smaller metal loads without paying for unused truck space
✔ Reduces overall shipping costs compared to full truckload (FTL) shipping
✔ Offers greater shipping flexibility for businesses with variable demand
However, due to the weight, size, and handling requirements of metal products, LTL shipments can be more complicated than in other industries.
Challenges of LTL Shipments in Metals
1. Risk of Damage During Handling
One of the biggest concerns with LTL shipments in metals is damage during transit. Since LTL shipments are handled multiple times at distribution terminals, there is a greater chance of:
🚧 Scratches and dents on steel sheets, coils, or aluminum parts
🚧 Bent or warped metal due to improper stacking
🚧 Rust or corrosion from exposure to moisture
💡 Example: A steel distributor ships cut-to-length sheets via LTL, but due to improper stacking at a terminal, the edges become bent, leading to rejected material upon delivery.
How to Prevent It:
✅ Use strong, durable packaging (wooden crates, steel banding, or reinforced pallets).
✅ Wrap metal in protective covers (plastic sheeting or corrosion-resistant coatings).
✅ Clearly mark “Do Not Stack” or “Fragile” to avoid mishandling.
2. Weight & Density Challenges
Metals are dense and heavy, making LTL shipments more difficult to price and handle. Unlike lightweight goods, metal shipments often exceed standard weight limits, leading to:
⚠ Higher freight class and shipping costs
⚠ Potential weight disputes with carriers
⚠ Increased risk of extra handling fees
💡 Example: A manufacturer shipping steel tubing via LTL is charged additional fees because the weight classification exceeds the carrier’s standard limits.
How to Prevent It:
✅ Accurately measure and declare weight to avoid reclassification fees.
✅ Work with LTL carriers experienced in heavy freight.
✅ Use custom pallets that distribute weight evenly to avoid additional fees.
3. Longer Transit Times
Unlike full truckload (FTL) shipments, LTL shipments go through multiple stops and sorting hubs, leading to:
⏳ Unpredictable delivery times
⏳ Increased risk of delays due to re-routing
⏳ Potential mix-ups or lost shipments
💡 Example: A metal fabricator orders an urgent supply of aluminum bars via LTL, but due to multiple handoffs at different terminals, the shipment arrives three days late, delaying production.
How to Prevent It:
✅ Plan ahead and allow extra time for transit.
✅ Choose priority LTL services for time-sensitive shipments.
✅ Work with reliable carriers that provide accurate tracking and delivery estimates.
4. Limited Carrier Availability for Oversized or Irregular Loads
Many metal shipments involve irregular shapes, such as long steel beams, large sheets, or heavy coils, which can be difficult for standard LTL carriers to accommodate.
🚛 Challenges Include:
✔ Limited trailer space for extra-long metal products
✔ Higher fees for oversized loads
✔ Rejections from carriers unwilling to handle non-standard freight
💡 Example: A construction company needs to ship 30-foot-long steel beams, but most LTL carriers can only handle shipments up to 12 feet long, forcing them to look for specialized carriers.
How to Prevent It:
✅ Work with specialized metal carriers that can handle long or irregular shipments.
✅ Consider using partial truckload (PTL) shipping if your metal products exceed standard LTL size limits.
✅ Use breakdown packaging where possible (e.g., cutting beams into smaller sections for easier transport).
5. Higher Risk of Freight Class Disputes
LTL carriers use freight class classifications to determine shipping rates, but metal products often fall into ambiguous freight categories, leading to disputes over pricing.
⚠ Common Issues:
✔ Discrepancies between actual vs. estimated weight
✔ Misclassification of metal type (steel, aluminum, copper, etc.)
✔ Extra charges for “non-stackable” shipments
💡 Example: A distributor ships stainless steel rods classified as Freight Class 50, but the carrier reclassifies them as Class 60, resulting in unexpected rate increases.
How to Prevent It:
✅ Double-check NMFC freight classifications before booking LTL shipments.
✅ Use accurate weight and dimension data to avoid carrier reclassification.
✅ Work with LTL freight brokers who specialize in metal shipments to secure the best rates.
6. Limited Insurance Coverage for High-Value Metals
Metals like stainless steel, copper, and aluminum are high-value materials, but standard LTL carrier liability limits may not fully cover potential losses.
🔴 Risk Factors Include:
✔ Theft of high-value metal shipments
✔ Insufficient compensation for damaged goods
✔ Loss during multiple handling points
💡 Example: A manufacturer shipping high-grade aluminum sheets via LTL experiences damage in transit, but the carrier’s liability policy only covers a fraction of the total loss.
How to Prevent It:
✅ Purchase additional freight insurance for valuable metal shipments.
✅ Work with trusted carriers that have a strong track record with metal logistics.
✅ Use secure packaging and GPS tracking for added protection.
How to Overcome LTL Shipping Challenges in the Metals Industry
🚀 Key Strategies for Success:
✔ Use strong, protective packaging to prevent damage
✔ Work with LTL carriers experienced in heavy freight
✔ Double-check freight classification and weight to avoid rate disputes
✔ Plan for longer transit times and select priority services for urgent shipments
✔ Insure high-value metal shipments to reduce financial risk
By following these best practices, businesses can reduce costs, minimize damage, and improve efficiency when shipping metals via LTL.
🚚 Need help optimizing your LTL metal shipments? Let’s discuss in the comments!
