Dunnage plays an important role in the transportation industry, yet shippers may not give it much consideration. That's a mistake: when a truck shows up to load without the right kind or quantity of dunnage for the job, shippers can face delays that disrupt their timelines, customer commitments, and budget.
Here at Anderson Trucking Service (ATS), our very first load in 1955 was an open-deck shipment. Seven decades later, open-deck and specialized freight remain at the core of what we do.
We’ve learned that having the right dunnage materials is vital to keeping freight safe and stable across thousands of miles — and we’ve also seen how a lack of planning at the dock can lead to delays, rework, or claims.
In this article, we’ll walk through what dunnage is and why it matters in truckload freight, the most common types of dunnage used in open-deck and van shipments, how much dunnage most drivers typically carry, and what you can do as a shipper to ensure you have the right materials on-hand.
By the end, you’ll have a clearer understanding of how to prepare your shipments so the truck that arrives at your dock is equipped to move your freight safely and efficiently from the start.
Dunnage Meaning: Scrap With a Purpose
In the transportation industry, dunnage refers to materials used during freight loading and securement processes. Primarily, dunnage acts as a buffer, separating cargo from the deck of a semi-trailer for open-deck shipments or keeping multiple pieces of freight from jostling around or rubbing against each other during transport.
Dunnage may be used as a packing material, pallet, or packaging for the freight, depending on the types of goods being transported. It also provides room for loading and unloading by forklift or crane.
Different Types of Dunnage Used in Freight Shipping
In the transportation industry, dunnage comes in all shapes and sizes. For parcel shipments, dunnage is technically considered anything from packing peanuts to bubble wrap. But when it comes to moving freight, dunnage looks a bit different.
Full-truckload freight shipments primarily use wood and/or plastic dunnage, which comes in structural and shock-absorbing configurations as well as inflatable and loose-fill options.
Wood Dunnage
Used in both dry van and open-deck shipping applications, wood dunnage is often used for heavy items or items prone to shifting or rolling in transit.
Common types of wood dunnage include wood blocks, pallets, planks, and lumber. It is generally affordable, absorbs shock well, and can easily be cut and customized to fit specific cargo shapes and sizes. Wood dunnage can also be beveled when necessary. Beveled dunnage is used to keep cylindrical and coiled freight from rolling across the deck of an open-deck trailer.
Both treated and non-treated wood can be used as dunnage, but non-treated options are far more common. Recycled wood is another option that can be both budget-friendly and sustainable, allowing companies to save money without compromising load security or green initiatives.
And speaking of recycling: dunnage such as wood blocking and pallets is typically reused when possible or sent to recycling facilities where it can be processed into mulch, composite wood products, or recycled fiber. With that said, wood dunnage is somewhat less reusable than plastic dunnage due to plastic's superior hardiness and ability to withstand moisture.
Common Wood Dunnage Sizes
A popular dunnage material for structural and shock-absorbing purposes, wood dunnage comes in a variety of sizes for stabilizing, blocking, and bracing cargo:
- Small/General Purpose: 2" x 4"
- Medium/Heavy Duty: 3" x 4", 4" x 4", and 4" x 6"
- Extra Heavy Duty: 6" x 6", 8" x 8", 10" x 10", and 12" x 12"
- Common Wood Dunnage Lengths: 4 ft., 5 ft, 6 ft., 8 ft., up to 12 ft.
Plastic Dunnage
Plastic dunnage is most commonly used for food and beverage freight, industrial freight, high-value shipments and fragile goods. Plastic dunnage is adept at absorbing shock to prevent damage to cargo during transit. It is also resistant to moisture, making it ideal for transporting chemicals, medical equipment and pharmaceuticals, and consumable goods.
Plastic dunnage sizes depend largely on its form. Plastic platforms are commonly used as alternatives to wood pallets, but there are a variety of different types of plastic dunnage that can be used in freight shipping:
- Corrugated Plastic Sheets: Plastic sheet dunnage is used to separate stacked product and prevent scuffing, chipping, or other damage during transportation. It is especially common in automotive and industrial shipping.
- Dunnage Bags (Void Fill): Inflatable plastic bags placed in gaps to cushion cargo and prevent shifting. This dunnage type is cost-effective and easily customizable depending on the unique needs of a shipment/cargo type. Typical sizes range from 90 x 120 centimeters to 150 x 250 centimeters.
- Plastic Dunnage Racks/Pallets: Both lightweight and heavy-duty, these pieces are used instead of wood pallets to prevent cargo from shifting or touching the floor during transit, which is critical for sanitation (for products at risk of contamination) and avoiding damage. Unlike wood, plastic racks and pallets are resistant to rust, corrosion, moisture, and are easy to clean and reuse. Common plastic dunnage rack sizes include 12-inch heights with widths of 24–36 inches and lengths ranging from 36 to 96 inches, though smaller footprints are also available.
- Plastic Foam: Provides superior cushioning and shock-absorption for delicate or high-value items. Commonly used when packing glass products and sensitive electronics for shipping. Like dunnage bags, plastic foam dunnage is adaptable to many different usages.
- Solid Plastic Dunnage: Plastic blocks or "lumber" used to secure and support heavy-duty loads. 88" and 96" lengths are standard for truckload shipping. Common profiles for plastic lumber and blocks include 4" x 4", 4" x 6", 5" x 5", and 6" x 6".
One significant benefit of plastic dunnage is its reusability and sustainability. Plastic dunnage can often be returned and reused thanks to its durability, which can help lower long-term transportation costs and environmental waste compared to single-use options.
Another benefit of plastic dunnage is its infinite customizability. Plastic dunnage pieces can be custom-designed and produced to address the specific needs and challenges of a shipment or freight type, making it ideal for complex loads or one-of-a-kind goods.
Alternatives to Traditional Dunnage
If sustainability is top-of-mind for your business but plastic options aren't a good fit, there are eco-friendly alternatives. Chief among them is paper dunnage, which can include cardboard, kraft paper, and corrugated paper. These lightweight, easy-to-work-with materials are sustainable, cost-effective, and versatile; you'll find them used as void filler, dunnage bags, and structural support.
While paper is less reusable than hardier plastic options, it is recyclable and biodegradable, making it better for the planet (and for companies concerned with minimizing their carbon footprint).
Depending on how your items are prepared for transit (i.e. crated, boxed, etc.), you may also consider uniquely eco-friendly gap fillers and bracing:
- Biodegradable packing peanuts are made from cornstarch and can easily replace Styrofoam products.
- Molded pulp/cardboard dunnage is made from recycled paper products, and its rigidity makes it ideal for bracing.
- Mushroom (mycelium) packaging is sturdy, fully-compostable, and can be custom molded into a variety of shapes to protect fragile items.
- Recycled air pillows use recycled plastic as a dunnage bag material and reduce the overall volume of material used.
Selecting Dunnage: Cost Considerations and Trade-Offs
Selecting dunnage is a cost control decision that influences damage risk, labor time, compliance exposure, and even freight efficiency.
At a basic level, shippers weigh the material cost of the dunnage itself. Wood blocking, corrugated void fill, foam, airbags, and custom elements all carry different price points. Heavier-duty solutions cost more upfront, but lighter or lower-grade materials may increase the likelihood of product damage.
Beyond material price, shippers should evaluate:
- Damage risk and claims exposure: Lower-cost dunnage that fails in transit can result in product loss, customer chargebacks, and higher insurance premiums.
- Labor and installation time: Some dunnage solutions require more time to cut, place, or secure, increasing warehouse labor costs.
- Weight impact: Heavier materials add to shipment weight, which can increase freight costs, particularly in truckload, air, or parcel shipments.
- Space efficiency: Bulky dunnage may reduce cube utilization, limiting how much product fits in a trailer or container.
- Dunnage regulations in international shipping: International shipments may require heat-treated or certified wood, adding cost but preventing customs delays or rejections.
- Disposal and sustainability considerations: Recyclable or reusable options may reduce long-term waste costs and support environmental goals.
In many cases, the lowest upfront cost is not the lowest total cost. The right dunnage balances material expense with risk reduction, operational efficiency, and the value of the product being protected.
How Improper Dunnage Can Cause Cargo Damage
Dunnage is more than filler; it's a strategic, structural element of your shipment. When dunnage is poorly selected, improperly placed, insufficient in quantity, or omitted altogether, normal transit forces can damage freight.
As a trailer accelerates, brakes, and turns, cargo is constantly under pressure. The use of dunnage can make or break the integrity of the goods transported; without proper blocking and bracing, loads can shift, rub, compress, or absorb uneven force.
If dunnage is stacked so that the configuration is taller than it is wide, weight distribution and balance can be affected, leading to load shifts. A safer alternative is cribbing, which involves using stacked, interlocking blocks to create a stable, temporary foundation for supporting, raising, or stabilizing heavy loads during transport.
In general, improper dunnage practices can lead to:
- Load shifts that damage adjacent freight or break securement devices
- Vibration wear from friction against trailer walls or other pallets
- Compression damage caused by uneven or poorly positioned support
- Moisture or contamination risks from low-quality or untreated materials
- Weight imbalance that affects stability and regulatory compliance
Most cargo damage is not the result of a single failure, but many small securement gaps that compound over miles. Over time, even minor load movement can compromise packaging and product integrity.
Matching the dunnage type and method to the freight’s weight, fragility, and mode of transport is essential to protecting the shipment from origin to delivery.
If you're uncertain what the best dunnage strategy is for your freight, talk with your transportation provider. An experienced carrier or logistics provider will be able to present you with your options and talk you through the pros and cons of each, so you can make the right decision for your shipment.
Related: 7 Ways to Protect Your Open-Deck Freight During Transport
How Much Dunnage Do Truck Drivers Typically Carry?
Open-deck truck drivers typically keep dunnage on hand. Exact amounts vary from driver to driver, but in general, you can expect an individual truck to have about 6 to 10 pieces of wood dunnage with them at any given time. These dunnage pieces could be of any size or length.
More specialized dunnage, like plastic dunnage or eco-friendly dunnage, is not universally carried by truckers, so do not assume your truck will have it on hand. Likewise, dry van drivers are not necessarily expected to keep dunnage on hand. In fact, it is far more common for shippers across trucking modalities to provide the necessary dunnage on-site at loading, especially if the dunnage required is non-wood.
How to Ensure You Have Enough Dunnage
No shipper wants to have a truck arrive at their facilities only to discover they don't have the right dunnage (or enough of it) on hand to properly load their shipments. The good news is that the best solution to this problem is also a free one: communication.
Dunnage should be sorted out well before any trucks are dispatched to your facilities. When arranging a shipment with your transportation provider, be sure to explicitly state the type of cargo you need moved and any special dunnage requirements you have, including quantity and sizes.
Ask your provider how much dunnage their trucks typically carry. If extra dunnage is required, ask if that's something your provider can arrange for, or if it will be your responsibility. If your provider can get extra dunnage for your truck, it may come with an associated fee, so be sure to clarify that up front.
It is common for shippers to keep extra dunnage on hand at their facilities. While typically offered for free, sometimes shippers charge their carrier per board. If you'll have dunnage on-site, communicate that to your provider in addition to any fees they may incur for using it.
By communicating these needs and expectations early, you can avoid delays and frustration stemming from dunnage-related issues.
Dunnage in Truckload Shipping: Plan It Before the Truck Arrives
Dunnage may seem like a minor detail, but in truckload shipping it directly affects load securement, damage risk, and cost. The right materials protect your freight and your margins. The wrong approach — or no plan at all — can lead to delays, claims, and strained customer relationships.
Small oversights at the dock can add up quickly, so before your next shipment moves, ask yourself: Have you selected dunnage based on total cost, not just material price? Does it match the weight, fragility, and mode of transport? Are responsibilities between your team and your carrier clearly defined?
If your plans check all these boxes, you're in good shape. When you treat dunnage as a strategic part of your shipment planning process, you reduce risk, protect your product, and keep freight moving as intended.
