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The Ultimate Guide to Oversize and Overweight Loads: What They Are and How to Get Permits

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  • GLI Dispatch Services
  • July 30, 2025

The Ultimate Guide to Oversize and Overweight Loads: What They Are and How to Get Permits

In the vast world of freight transportation, not all cargo fits neatly into the back of a standard trailer. Some shipments stretch far beyond the limits set by federal and state regulations—these are classified as oversize or overweight loads. Transporting such freight is no small feat. It requires strategic planning, regulatory compliance, and special permits to legally move through jurisdictions.

This article is designed to serve as a complete guide for carriers, brokers, shippers, and logistics companies handling these complex freight types. We’ll explore what qualifies as oversize/overweight freight, when and how to apply for permits, and what responsibilities fall on those involved in the transport process.

What Is an Oversize or Overweight Load?

An oversize load is a shipment that exceeds one or more of the legal size dimensions (width, height, or length) defined by transportation authorities. An overweight load, on the other hand, is any cargo that exceeds the maximum allowable weight, either by gross vehicle weight or axle weight limits.

These limits vary slightly from state to state but generally adhere to the following national standards in the United States:

  • Maximum width: 8 feet 6 inches (102 inches)
  • Maximum height: 13 feet 6 inches
  • Maximum length: 48 to 53 feet, depending on the trailer and jurisdiction
  • Maximum gross vehicle weight: 80,000 pounds (including truck, trailer, and cargo)

If a load exceeds any of these dimensions, even by a few inches or pounds, the carrier is legally required to obtain an oversize/overweight permit.

Examples of Oversize/Overweight Freight

Oversize and overweight freight is most common in industries like construction, mining, energy, and manufacturing. Common examples include:

  • Large construction equipment (e.g., excavators, cranes, bulldozers)
  • Wind turbine blades or tower sections
  • Oil and gas field machinery
  • Modular homes and prefabricated buildings
  • Bridge beams and large steel components
  • Oversized generators and industrial transformers

These loads are not only massive in size but often also irregular in shape, requiring custom trailers and handling protocols.

Why Are Permits Required?

Transporting freight that exceeds standard legal limits puts stress on infrastructure such as roads, bridges, and tunnels. It can also pose risks to other motorists if not handled with caution.

Permits ensure:

  • Safe routing that avoids low bridges, tight turns, and restricted roads
  • Infrastructure protection by restricting access to vulnerable roads and bridges
  • Public safety by mandating escort vehicles, signage, and designated travel times
  • Carrier accountability for damage, violations, or emergencies during transport

Operating without proper permits can result in severe fines, shipment delays, and potential liability for damages.

Types of Permits

There are various types of permits depending on the load, route, and jurisdiction:

1. Single Trip Permits

Valid for one trip from point A to point B within a specified time frame. Most common for one-off or custom shipments.

2. Annual or Blanket Permits

Issued for a set period (often 12 months), allowing repeated trips with similar dimensions and weight limits within specific states or regions.

3. Superload Permits

Required when a shipment far exceeds standard oversize limits. These permits involve special review, route surveys, engineering analysis, and longer lead times.

When Do You Need an Escort?

Certain oversize loads require escort vehicles, also known as pilot cars, which travel ahead of or behind the load to ensure safety and help navigate traffic or obstacles.

While rules vary by state, escort vehicles are generally required when loads exceed:

  • Width: 12 feet
  • Height: 14 feet
  • Length: 90 to 100 feet

Escort vehicles must be equipped with:

  • Warning signs (“OVERSIZE LOAD”)
  • Flashing amber lights
  • Radios for communication with the driver

In some cases, police escorts may be mandated, especially in urban areas or on high-traffic routes.

How to Apply for an Oversize/Overweight Permit

Obtaining permits can be time-consuming, especially if your route crosses multiple states. Here’s a step-by-step process to guide you through the application:

Step 1: Gather Load Specifications

Accurate measurements are non-negotiable. You’ll need:

  • Exact dimensions: width, height, length
  • Gross vehicle weight and axle weight breakdown
  • Axle spacing (distance between axles)
  • Description of load (machinery, building materials, etc.)

Step 2: Identify Jurisdictions

Each state has its own permitting authority, typically managed by the Department of Transportation (DOT) or equivalent. If your route crosses multiple states, you’ll need separate permits from each.

In some urban areas, local municipalities or counties may also require their own permits.

Step 3: Use State Portals or a Permit Service

Most states offer online application portals, such as:

  • TxPROS (Texas)
  • SCOPUS (South Carolina)
  • Connect NCDOT (North Carolina)

Alternatively, many carriers choose to work with permit service providers who handle the process on their behalf. These services often speed up approvals and ensure compliance.

Step 4: Plan the Route

Routing is a critical part of the permit process. You may be restricted from:

  • Passing through narrow streets
  • Crossing certain bridges
  • Traveling during peak hours, holidays, or inclement weather

Some states provide routing tools, while others require route approval based on engineering review.

Step 5: Pay Fees

Fees vary by:

  • State
  • Load dimensions and weight
  • Distance
  • Duration of the permit

A single-trip permit typically costs anywhere from $20 to over $300 per state. Superloads and specialized permits can cost significantly more.

Step 6: Print and Carry the Permit

Once approved, carry printed copies of the permit in the truck. You’ll need to present this at checkpoints or in case of inspection. The permit will detail:

  • Approved routes
  • Valid dates and times
  • Required escorts and safety measures

What Happens if You Violate Permit Terms?

Violating permit conditions is a serious offense and can result in:

  • Hefty fines
  • Delays or rerouting
  • Possible impoundment of the vehicle
  • Liability for road or bridge damage
  • Blacklisting from future contracts or jurisdictions

Examples of violations include:

  • Exceeding the permitted dimensions or weight
  • Driving outside of allowed hours
  • Taking an unauthorized route
  • Failing to display proper signage or lighting

Always follow the exact instructions listed on your permit.

Equipment Considerations for Oversize Freight

Moving large loads requires specialized equipment. Common trailer types include:

  • Lowboys: Ideal for tall equipment like excavators
  • Extendable flatbeds: For long cargo like bridge beams
  • Double drop trailers: Designed to handle height restrictions
  • Multi-axle configurations: To distribute weight for heavy hauls

In addition, make sure your truck is properly maintained and equipped with:

  • Working lights and brakes
  • Flag holders and signage mounts
  • GPS and routing systems
  • CB radios for escort communication

Common Challenges in Oversize Freight Permitting

1. Last-Minute Changes

Changes in pickup or delivery location may affect route eligibility and require re-permitting.

2. Bridge Restrictions

Bridges often have weight or clearance limits that standard GPS systems won’t flag. Always rely on route-specific guidance.

3. Weather Delays

Many states prohibit oversize transport during poor weather. Check conditions daily and plan for flexibility.

4. Permit Processing Time

Superload permits can take several days or even weeks to process. Never wait until the last minute.

Best Practices for Success

  • Double-check everything: Even minor errors on applications can cause costly delays.
  • Maintain strong relationships with DOT officials: Clear communication can ease the permitting process.
  • Invest in training: Drivers, dispatchers, and operations teams should understand oversize protocols.
  • Keep documentation handy: Invoices, permits, load measurements, and insurance should always be accessible.
  • Use technology: Load planning software and GPS tracking systems can streamline routing and compliance.

Final Thoughts

Transporting oversize and overweight loads is a responsibility that extends far beyond getting from point A to point B. It’s about protecting infrastructure, ensuring public safety, and complying with the law. From accurate measurements and multi-jurisdictional permits to escort coordination and route planning, every detail matters.

Whether you’re a first-time carrier or a seasoned heavy-haul specialist, understanding the full process of oversize permitting will keep your operation legal, efficient, and profitable. Taking the time to do it right pays off in fewer fines, faster deliveries, and a solid reputation in the freight industry.

GLI Truck Dispatch Services offers one of the best truck dispatch services to owner operators and carriers across USA. We offer other back-office solutions such as compliance and accounting to carriers in addition to our truck dispatch services to help our carriers succeed in this competitive yet rewarding trucking industry. At GLI, our truck dispatchers don’t just dispatch, they go the extra mile to help build relationships to help carriers grow their business. Its where professionalism meets quality. Visit www.glitruckdispatchservices.com to learn more about our processes and how our method of truck dispatching can help you succeed and grow your business. 

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