The $5,000 sign that arrives broken — and who pays. Freight damage = 3–5% of uncrated LTL shipments (industry data). Custom crate = $200–$500; damage claim = $2,000–$15,000 + 2–4 week delay. We crate every sign — included in price, not an upsell.
The $5,000 Sign That Arrives Broken — And Who Pays
We’ve seen clients receive crushed crates from fabricators who shipped “naked” on a pallet. The carrier denies the claim (improper packaging). The fabricator ghosts. The client waits 3 weeks for a remake. We crate every sign — A-frame wood, foam-lined, shock-indicated — included in every quote.
How We Crate Channel Letters (Factory Standard)
| Letter Type | Crate Style | Materials | Max Size |
|---|---|---|---|
| Front-lit / Face-halo | A-frame wood crate, foam-lined | 1/2″ plywood, 2″ EPS foam, corner protectors | 120″ single piece |
| Infinity mirror | Custom A-frame, climate-controlled | 3/4″ plywood, 3″ foam, mirror-specific corners, desiccant | 80″ single piece |
| Dynamic/Neon | Reinforced A-frame, shock-mount | 3/4″ plywood, 2″ foam + vibration dampeners | 100″ single piece |
| Multi-piece (spliced) | Modular crates, labeled segments | Same + alignment pin protectors | Unlimited |
Inside the Crate — Protection Layers
- Face protection: 3M surface protection film (removable, no residue)
- Corner guards: high-density foam + corrugated cardboard wraps
- Return/back protection: foam pads at all contact points
- Internal bracing: foam blocks prevent letter-to-letter contact
- Desiccant packs: 2–4 units per crate (humidity control for mirrors/electronics)
- Shock indicators: Tip-N-Tell / ShockWatch on exterior (evidence for claims)
Shipping Methods & Lead Times
| Method | Transit (US) | Best For | Cost Adder |
|---|---|---|---|
| LTL (palletized) | 3–7 business days | Standard, ≤120″ | Base |
| Dedicated truck | 2–5 days | >120″, multi-crate, time-critical | +40–60% |
| Air freight | 1–2 days | Emergency, international | +150–200% |
| Ocean (container) | 20–35 days | International bulk (10+) | Base (volume) |
International Shipping — What Changes
- ISPM-15 heat-treated wood (stamped) — mandatory for customs
- Climate-controlled container (infinity mirror, dynamic) — +15% cost
- Commercial invoice + packing list + certificate of origin (we provide)
- DDP (Delivered Duty Paid) available — we handle brokerage
- Ships to: US, Canada, EU, UK, AU, NZ, UAE, SG, HK, JP, KR, MX
Receiving Checklist — Do This Before Signing the BOL
- Count crates vs BOL — note shortages immediately
- Inspect exterior — crush marks, punctures, water stains, tipped indicators
- Shock indicators — red = potential internal damage (photo + note on BOL)
- Open carefully — remove bands, lift lid (don’t pry)
- Inspect each letter — face scratches, return dents, corner cracks, LED test
- Power test — we include 120V pigtail for quick bench test (2 min/letter)
- Document everything — photos + video + written notes on BOL before driver leaves
- Claims window: 24–48 hours for concealed damage (carrier-dependent)
Common Damage Types & Root Causes
| Damage | Root Cause | Prevention |
|---|---|---|
| Face scratches | Forklift tine contact, crate shift | Face film + foam face pad + internal bracing |
| Return corner dents | Crate corner impact | HD foam corner guards + double-wall corners |
| Cracked acrylic | Vibration + thermal shock | Foam suspension + climate control |
| LED module loose | Vibration fatigue | Factory torque spec + threadlocker |
| Driver failure | Moisture ingress | Desiccant + sealed driver box |
| Mirror delamination | Thermal cycling | Climate control + desiccant + mirror corners |
Claims Process — We Handle It
- Photo/video evidence → we file claim with carrier (our account, our relationship)
- Replacement fabricated: 5–10 days (priority queue for damage)
- No cost to you — we absorb deductible, manage carrier
- 98% claim approval rate (proper crating = carrier liability clear)
Site Storage Before Install
- Indoor, climate-controlled (60–80°F, 30–50% RH) — ideal
- If outdoor: covered, off ground, shaded, <2 weeks max
- Infinity mirror/dynamic: NEVER outdoor storage — climate control mandatory
- Stack: max 2 crates high, heaviest bottom, arrows up
Install-Day Logistics
- Crate delivery → install same day preferred (minimize site storage)
- We coordinate: crate delivery time = crew arrival time
- Crate removal: we take empty crates (recycle/reuse) — no dumpster fee
- Lift gate / forklift: specify at order — we arrange
Your Receiving SOP (Copy-Paste for Your Team)
[ ] BOL count matches PO [ ] Exterior inspected: no crush, puncture, water, tip [ ] Shock indicators: all clear (green) [ ] Crates opened: face film intact, foam in place [ ] Each letter: face clean, returns straight, corners sharp [ ] Power test: all LEDs illuminated, no flicker [ ] Photos taken: crate exterior, each letter, any issues [ ] Notes on BOL: "Received in good condition" or "Damage noted — see photos" [ ] Driver signature obtained [ ] Notify PM within 1 hour
Ready for damage-free delivery? Request our crate spec sheet — see exactly how your sign ships.
