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Reviewed and updated by ICD - Week 24/2026
Quick summary:
- Wrong technique - not the bag itself - is the leading cause of cargo damage with dunnage bags.
- The 8 serious mistakes: under-inflation, wrong AAR level, no edge protection, max-void violation, wrong size, skipping the gauge gun, ignoring moisture, and reusing a damaged bag.
- The single worst error is under-inflation - a bag below working pressure cannot hold the load.
- A gauge gun and the right material and AAR level prevent most failures.
8 serious dunnage bag mistakes to avoid
Used right, a dunnage bag secures cargo reliably; used wrong, it becomes the cause of damage. For the fundamentals, see what a dunnage bag is.
Mistake 1: Under-inflation
The most common and most serious error. The standard working pressure for a Level 1 bag is about 0.2 bar (2.9 PSI). Inflate below this (say 0.1 bar) and the bag cannot create enough static compression to hold the load. When the container meets dynamic force (braking, sway, rail shunting), an under-inflated bag compresses easily and lets the load shift far - and once it starts shifting, the whole stack can collapse, endangering workers at the destination. The root cause is usually a manual gun with no gauge, inflating by feel. Use a dedicated gauge gun: 0.2 bar is not just a spec, it is the precondition for the bag to absorb shock.
Mistake 2: Wrong AAR level
A strategic risk, especially for exports to strict markets or harsh routes. Using a Level 1 kraft bag for very heavy goods (over 20 tonnes) or intercontinental rail/sea (which need Level 3+) means the shell lacks the tensile and mechanical strength; under strong dynamic force it tears or deforms rather than pushing back, causing serious shifting or even import rejection for breaching AAR safety. For heavy goods and rail, use woven PP or Level 3+ kraft with AAR certification. See quality standards.
Mistake 3: No edge protection
A basic operating error that causes the most bag damage. Placing a kraft bag directly against the sharp edges of a wooden pallet, a metal bar or a damaged carton corner means the internal pressure pushes the shell hard against the edge; continuous (especially micro) vibration then cuts or tears it, deflating the bag and losing its bracing. Even a small hole bleeds pressure over days. Always pad with thick cardboard, foam or thin plywood between the bag and sharp corners - mandatory with kraft on wooden pallets.
Mistake 4: Max-void violation
A bag only works within its rated void range. Use it in a gap wider than its max void (for example a 100 cm bag for a 70 cm gap) and it over-rounds into a sphere instead of a flat cylinder, cutting contact area and bracing. For a too-large void, add rigid filler first. See the technical metrics guide.
Mistakes 5-8: size, gun, moisture and reuse
- Wrong size: a bag too short to cover 2/3 of the load height lets the upper layers topple in a sway; too narrow a bag cannot fill the gap evenly.
- Skipping the gauge gun: inflating by feel leads straight to over- or under-pressure. Always use a gun with a pressure gauge or auto-cutoff.
- Ignoring moisture (kraft): storing or using kraft bags damp lowers their mechanical strength. Keep them dry and use PE-coated kraft for humid sea routes.
- Reusing a damaged bag: a woven PP bag with a torn shell or worn valve will not hold pressure. Inspect before reuse and retire any with structural damage.
Frequently Asked Questions (FAQ)
What is the most common dunnage bag mistake?
Under-inflation. A bag below its working pressure (about 0.2 bar for Level 1) cannot hold the load when it surges.
How do I stop the bag tearing?
Pad sharp edges with cardboard, foam or plywood, and use woven PP for sharp-edged goods.
Why use a gauge gun?
Inflating by feel causes over- or under-pressure. A gauge or auto-cutoff hits the exact working pressure.
Can I reuse any dunnage bag?
Only undamaged woven PP bags. Inspect the shell and valve first; retire anything with structural damage.
Contact ICD Viet Nam
For the right dunnage bag and correct-use guidance, contact our team for a quote.
- Northern Vietnam: 0983 797 186 / 090 345 9186 / 090 5859 186
- Southern Vietnam: 098 6784 186
- Email: sales@icdvietnam.com.vn
- Zalo: Chat on Zalo
