The Importance of Proper Crating in Sign Shipping

By Derrick Donnell, Production Supervisor - Federal Heath

At Federal Heath, we pride ourselves on the quality of the signage we produce and on ensuring it arrives at its destination in the same pristine condition in which it left our facility. Whether we are shipping a large pylon sign across the country or a set of channel letters nearby, how that signage is packed and protected during transit can mean the difference between a successful installation and a costly, time-consuming issue. 

Protection from Physical Damage 

Exterior signs are investments for us as fabricators and our clients who rely on them to represent their brand. Many of these signs are made from aluminum, acrylic, glass, vinyl, and complex electronic components such as LED modules or digital displays. Though durable in their final installed form, these elements are susceptible to damage during shipping. Scratches, dents, bent frames, or shattered acrylic faces not only impact the visual appeal of the sign but can render it unusable altogether. 

Proper crating offers a first line of defense against these potential hazards. WDepending on the sign type, weuse sturdy wood crates or reinforced corrugated boxes, complete with custom foam padding, internal bracing, and moisture barriers. This system absorbs shock, minimizes movement, and prevents components from rubbing against each other. The goal is to ensure that the sign is immobilized within the crate and that external forces, such as vibrations, impacts, or compression from stacking, do not translate into internal damage. 

The type of lumber used for crating is also essential. Using #2 lumber for crating is preferred because it strikes a practical balance between strength, cost, and availability. It is a reliable choice for building crates that need to withstand handling and shipping. It is structurally sound and has enough strength to handle the stresses of shipping and storage. It contains moderate knots and defects but still meets standards for load-bearing capacity—crucial for crates that might carry heavy or fragile goods. 

Handling and Logistics Efficiency 

Another important reason for robust crating is handling efficiency. Many signs we fabricate are large, heavy, or oddly shaped, making them difficult to manage without the proper support. Crates with forklift runners or built-in lifting points make it far easier—and safer—for shipping crews to load, unload, and move the signs during every leg of the journey. This reduces the risk of accidental drops or collisions that can occur with loose, unprotected items. 

In addition, our crates are clearly marked with handling instructions like “This Side Up,” “Fragile,” and “Do Not Stack.” These visual cues help logistics teams understand how the items should be treated and ensure they are stored or appropriately transported throughout the supply chain. 

Financial and Reputational Considerations 

From a financial standpoint, investing in high-quality crating ultimately reduces costs. While the upfront materials and labor involved in building a custom crate may seem significant, they pale compared to the expenses involved in repairing or replacing a damaged sign. These costs include materials and labor, expedited shipping, additional project management time, and potential penalties if client deadlines are missed. 

Moreover, the impact on our reputation cannot be overstated. Our clients expect excellence—not just in the fabrication of the sign, but in the overall experience of working with us. Taking the time to crate each sign properly demonstrates our professionalism and commitment to quality, from design through delivery. 

Industry Best Practices 

•  Use custom-sized wooden crates or reinforced corrugated crates for lighter signs. 
• Include shock-absorbing foam, corner protectors, and internal bracing. 
• Ensure crates are labeled clearly with handling instructions like “This Side Up,” “Fragile,” or “Do Not Stack.” 

Proper Handling of Crates at the Installation Site 

Once the sign crates arrive at the job site, proper handling becomes as essential as the care taken during fabrication and shipping. Crates should be carefully inspected upon arrival for any visible signs of damage, and this should be documented with photos before they are moved or unpacked. This is not only a best practice for liability purposes but also ensures that any concealed damage can be traced back to the shipping process rather than handling at the site.  

Only qualified personnel using the appropriate equipment—such as forklifts or pallet jacks—should move the crates, following the “This Side Up” and “Do Not Stack” instructions marked on the exterior. 

Before uncrating, it is essential to place the crate on a level surface in a clean, dry area free from debris and excessive foot or equipment traffic. Installers should use the correct tools to remove panels, bracing, and protective materials, avoiding forceful or careless actions that could damage the sign. A methodical, careful approach ensures the sign remains in excellent condition and is ready for installation without delays or costly on-site repairs. 

Conclusion 

In the sign industry, presentation is everything, including how products arrive. Crating is not just a logistical necessity; it's a strategic part of the sign fabrication process. By taking crating seriously, we safeguard our work, our client relationships, and our company’s reputation. Every sign we build deserves to be protected—and every client deserves to receive it just as we intended.