IM Export Services packs and ships a wind tunnel facility to the US

Overview

When we were approached by an internationally renowned engineering firm specialising in factory relocations, we knew it would be a complicated project. However, the sheer scale, sensitivity and uniqueness of relocating an entire wind tunnel facility for one of the world's highest levels of motorsport from the UK to a leading electric car manufacturer in the US turned out to be even bigger than we expected.

Wind Tunnel Facility

The planning process

• Site visits & planning: We conducted multiple site visits to assess the layout, identify dismantling procedures, and plan container and flat rack requirements.

• On-site packing team: Our packing team carefully planned the packaging sizes to reduce unnecessary costs and simplify the transportation process for the larger components.

• Freight logistics: To manage the shipping logistics, our sister company IM Freight Forwarding, specialists in air and sea freight, arranged containerised transport and flat rack shipments specifically tailored for oversized units.

• Flexible strategy: Due to the limited space on-site, we instead transported components to our own facility in Redditch for packing, which then allowed the dismantling team to continue their work uninterrupted.

• Collaboration: Throughout the project, our packing and freight teams worked closely together to keep everything running smoothly. We also stayed in regular contact with the car manufacturer and engineering teams responsible for decommissioning and reinstallation.

We delivered bespoke packing solutions for each component, securely packing fragile plyboard tunnel sections, modularising the steel framework for efficient handling and designing low-height packaging for oversized fan unit pieces, each weighing over 15 tons, complying with a 4-metre transport height limit.

Additionally, the delicate 25-ton rolling road was safely transported using protective methods and manufacturer-advised bracing, while sensitive robotic and measurement equipment were carefully enclosed in secure cases.

Challenges Identified

• Sensitive cargo: Wind tunnels required extreme precision - any transit damage could affect their performance.

• Restricted space: Limited building access made dismantling and removal difficult, with many structural and packaging needs only becoming clear during the process.

• Oversized & heavy cargo: Several parts, including fan units and the rolling road, weighed between 15 and 25 tons, requiring specialist handling.

• Freight disruptions: Global shipping issues such as rerouted vessels, extended transit times and rising costs added unpredictability.

  
  

Results 

Despite delays caused by dismantling complications, the project quickly gained momentum, resulting in the successful shipment of over 40 freight units, including flat racks and containers. We effectively managed freight disruptions, altered shipping routes, and port challenges, resulting in the safe delivery of the wind tunnel to the US.

Conclusion 

Every project has its own challenges and at IM Export Services, we know how to adapt, especially when managing complicated tasks. Our approach helps reduce risk, save time and provide accurate packing estimates even before dismantling begins.

Rob Johnston, Managing Director of IM Export Services, said: “We're more than just a packing company. We provide the support and guidance in helping our clients streamline their operations and protect their equipment from start to finish.”

Need specialist packing or out-of-gauge freight support? Contact IM Export Services or IM Freight Forwarding for further information.