In the construction materials industry, it’s common for a single job site order to include everything from full pallets of heavy block to small, fragile items like boxes of hardware or sealants. These mixed-size material loads present unique challenges during dispatch—especially when accuracy, space efficiency, and delivery timing are critical.
If you’re just starting out in logistics or warehouse management, understanding how to optimize these loads will help you cut costs, reduce damage, and deliver a better experience to contractors.
Here’s a step-by-step guide to help you get started.
What Are Mixed-Size Material Loads?
Mixed-size loads refer to shipments that include a combination of:
Full-pallet items (e.g., drywall, brick, insulation)
Medium-sized packaged goods (e.g., paint buckets, piping)
Small, boxed, or loose items (e.g., fasteners, adhesives, fittings)
Fragile or irregularly shaped materials
These loads require careful planning to ensure materials are protected, correctly loaded, and delivered in a way that allows easy unloading at the job site.
Why Optimization Matters
Improperly planned mixed-size dispatches can result in:
Underutilized truck space, leading to higher fuel and labor costs
Material damage due to poor stacking or unsecured items
Longer loading times in the warehouse
Contractor frustration if items arrive in the wrong order or are hard to unload
Optimizing your dispatch process helps you improve efficiency, accuracy, and customer satisfaction.
Step 1: Understand What You’re Shipping
Before you plan a load, you need to know the:
Size, weight, and packaging type of each item
Fragility or stacking restrictions
Delivery sequence (if the truck has multiple drops)
Equipment needed for loading/unloading (e.g., forklift, liftgate)
Pro tip: Use item profiles in your warehouse system or ERP to quickly reference material handling requirements.
Step 2: Stage Materials by Load Priority
Group materials in the warehouse by delivery route and drop-off order. This ensures items are loaded efficiently and come off the truck in the correct sequence.
Best practices:
Stage fragile or loose items last, so they’re loaded last and offloaded first
Pre-stage pallets in zones by route or job site
Use clear labeling with order numbers and delivery instructions
Step 3: Use Load Planning Tools
Digital load planning tools help you:
Maximize truck space
Plan item placement by size, weight, and order
Prevent overloading or improper stacking
Visualize load layout before actual loading begins
Even basic load optimization software can save time and reduce loading errors.
Step 4: Train Staff on Mixed-Load Handling
Your loaders and drivers need to know how to:
Safely stack different materials (e.g., no drywall under concrete block)
Secure items to prevent shifting
Protect fragile materials using padding, shrink wrap, or barriers
Handle unusual items like rebar, PVC pipe, or glass panels
Tip: Conduct periodic training refreshers using real-world examples from past delivery issues.
Step 5: Match the Right Truck to the Right Load
Not all loads require a flatbed or full box truck. Smaller mixed orders can often be handled with sprinter vans or light-duty trucks.
How to choose:
Consider the total volume and weight
Assess site access limitations
Check whether the load requires forklift unloading or manual handling
Using the right vehicle can reduce cost per trip and avoid job site delivery complications.
Step 6: Communicate Clearly with the Job Site
Contractors need to know:
What’s coming
When it’s arriving
How it’s packaged
Any special instructions for handling
Use delivery notifications, job site check-in calls, or apps to share updates—especially if the order includes fragile or high-value materials.
Step 7: Use Digital Proof of Delivery (POD)
Once delivered, capture:
Photos of the load at the job site
Digital signatures or notes from the receiving contact
Timestamps and geolocation data
This protects you from disputes and confirms that all parts of the mixed load were delivered accurately and in good condition.
Final Thoughts
Mixed-size material dispatch is a challenge, but it’s also an opportunity. When done right, it can increase truck efficiency, reduce material waste, and strengthen relationships with contractors.
By understanding your materials, using the right tools, and training your team effectively, you can turn dispatching complexity into a logistics advantage—even as your business grows.
