How to Avoid the Most Common Dunnage Airbag Installation Failures

Introduction 

When you’re shipping large loads, dunnage airbags (also called air dunnage bags or simply dunnage bags) are one of the most effective tools to keep cargo from shifting. Yet even though they seem simple, common mistakes in installation can defeat their purpose and lead to damaged goods, claims, and unhappy customers. In this guide, we’ll walk through the top failures in dunnage airbags and how to prevent them, with tips you can apply immediately. 

Please review our blog on Common Mistakes in Dunnage Airbag Installation and How to Avoid Them 

Why Proper Use of Dunnage Airbags Matters 

Before diving in: what do dunnage airbags really do? These inflatable cushions are placed between cargo units to fill voids, stabilize the load, and prevent lateral motion. When done correctly, they reduce product damage, avoid delays, and save you money. 

Various types exist. Poly woven dunnage bags are robust and reusable; paper (kraft) dunnage air bags are often lower cost and more disposable. When choosing a dunnage bag for your operation, your decision between paper, poly woven, or hybrid constructions should depend on load, distance, reuse needs, and environmental exposure. 

Also keep in mind: air dunnage bags (and inflatable dunnage air bags) must comply with industry standards (e.g. AAR, ASTM, ISO) to ensure reliability and safety.  

Top Mistakes in Dunnage Airbag Installation (and How to Avoid Them) 

Below are the most frequent errors you’ll see in the field — along with how to fix or prevent them. 

  1. Incorrect Sizing of the Bag


Mistake: Choosing a dunnage bag that’s too small or too large for the void. 

  • If the dunnage bag is too small, it won’t press snugly and may shift or collapse. 



  • If it's too big, it can overpress against cargo or burst seams. 


Fix / Prevention: 

  • Accurately measure the gap (void) between cargo stacks using a tape or void gauge. 



  • Select a dunnage airbag whose nominal fill range matches that void (neither excessive bulge nor slack). 



  • If the void is unusually wide, consider a custom size or specially designed bag rather than simply placing two side‑by‑side. (Using two smaller shipping air bags side by side often causes instability.) 



  1. Over‑Inflation or Under‑Inflation


Mistake: Guessing how much air to pump into the bag (either overfilling or underfilling). 

  • Overfilling strains seams and may burst the bag, particularly under temperature change or load shift. 



  • Underfilling leads to sagging, poor contact, and ineffective securing of the load. 


Fix / Prevention: 

  • Always use a calibrated pressure gauge or a professional Airbag inflator tool; do not inflate by feel. 



  • Adhere strictly to the PSI (or bar) specification printed on the dunnage bags. 



  • Monitor pressure over time (before sealing the container, after a short settling period) to ensure no leaks or drift. 



  • Understand how environmental changes (temperature, altitude, etc.) may affect internal pressure.  


Please read our detailed guide on Understanding Dunnage Airbag Inflators: How They Work 

  1. Misplacement or Skewed Positioning


Mistake: Placing the bag crooked, leaning, pressed against sharp edges, or touching the floor or pallet surface. 

Consequences: 

  • Edges and corners may tear the bag. 



  • The load may shift vertically or laterally. 



  • The bag may not expand evenly, leading to gaps or weak spots. 


Fix / Prevention: 

  • Place the air dunnage bag so it sits flat, centered, with full contact on both sides of the void. 



  • Avoid placing the bag directly against sharp corners; use edge protection or padding. 



  • Raise the bag slightly off the floor if the container floor is rough or contaminated (especially if using paper style dunnage bags). 



  1. Ignoring Environmental and Condition Factors


Mistake: Assuming bags will perform the same under every condition. 

  • Poly woven dunnage bags may stretch or soften in heat, or degrade in humid, wet environments. 



  • Bags stored improperly (sun exposure, contact with chemicals) may weaken before use. 



  • Reusing heavily stressed or fatigued bags without inspection. 


Fix / Prevention: 

  • Choose a bag material appropriate for your route: poly woven for long or harsh trips; paper-based for short runs or one-way shipping. 



  • Rotate stock, inspect bags before use, and avoid storing in extreme sunlight, heat, or moisture. 



  • Discard or retire inflatable dunnage air bags that show signs of wear, seam damage, or leakage.  



  1. Skipping Bracing, Edge Protection, or Vertical Restraint


Mistake: Relying entirely on the dunnage airbags, without supporting braces or shielding. 

Consequences: 

  • Even with correctly sized and placed bags, loads may shift vertically or overcome the lateral restraint. 



  • Sharp corners or pallet edges can rub and result in bag puncture. 


Fix / Prevention: 

  • Use top and bottom bracing (e.g. load bars, pallets, straps) to prevent vertical movement. 



  • Place protective materials (e.g. plywood, corrugated sheets) over edges or corners that may come into contact with the bag. 



  • Ensure walls or container sides are suitably rigid to resist outward pressure. 



  1. Lack of Training, SOPs, and Quality Inspections


Mistake: Leaving installation to guesswork or untrained staff. 

  • People skip instructions or “wing it.” 



  • No consistent inspection routines. 



  • No feedback loop or error tracking. 


Fix / Prevention: 

  • Develop clear Standard Operating Procedures (SOPs) with visual aids, checklists, and step-by-step guidance. 



  • Train staff (hands-on, not just theory) in measurement, inflation, placement, and inspection. 



  • Perform a final quality check before sealing the load: verify correct bag size, pressure, alignment, and absence of damage. 



Quick Installation Checklist 

Before you finalize your load, run through this checklist for each dunnage bag used: 

  1. Void measured and matches bag’s fill range 



  1. Bag type (paper or poly woven) suits the trip and load 



  1. Inflation pressure is exactly at the recommended level 



  1. Bag is centered, flat, and not leaning or skewed 



  1. No contact with sharp edges; edge protection in place 



  1. Bracing above and below, where needed 



  1. Bag inspected for damage or leaks 



  1. Valve securely closed and sealed 



  1. Recheck after a short settling period to ensure no pressure loss 


Please check our guide on Dunnage Air Bag Best Practices: A Step‑by‑Step Cargo Securement Guide 

Choosing Dunnage Bags for Your Operation 

Material & Type Comparison 



























Material / Type  Pros  Cons  Best Use Cases 
Paper / Kraft style  Low cost, recyclable, sufficient for short routes  Sensitive to moisture, less durable for reuse  Short-haul, one-way shipments, light to medium loads 
Poly woven / Vinyl  Strong, reusable, moisture-resistant  Higher cost, more difficult to recycle  Long-haul, mixed-mode transport, heavier or sensitive loads 
Customized / hybrid designs  Tailored fit, advanced performance  More expensive, longer lead time  Unusual gap sizes, critical loads, repeated use 

When evaluating dunnage bags for sale, look for full specification sheets, burst test ratings, certification (e.g. AAR, ISO), and documentation from the air dunnage bag manufacturers. Avoid products that lack clarity on pressure limits, material construction, or quality assurance. 

Please read our blog on: Why Do Rail Shipments Require AAR-Verified Dunnage Air Bags? 

Vendor & Support Considerations 

  • Choose air dunnage bag manufacturers who offer training, installation support, or on-site consulting. 



  • Request sample or demo units to test in your own load environment. 



  • Verify quality control practices: e.g. batch testing, pressure hold tests, valve performance. 



  • Check warranties or replacement policies on shipping air bags. 


 

Conclusion 

Missteps in dunnage airbags (or air dunnage bags) installation may seem small, but their consequences are real — shifting cargo, increased claims, and wasted time. The most common failures (incorrect sizing, bad inflation, poor placement, environmental oversight, skipped bracing, and lack of training) are preventable if you follow a disciplined process. 

By combining the right dunnage bags, consistent staff training, clear SOPs, vendor support, and a reliable inspection checklist, you’ll reduce failures dramatically. Start small, audit your current usage, and iterate. 

If you’re looking for a trusted partner to guide you through selection, certification, and training, Dunnage Systems Inc. can help you implement a robust and reliable dunnage airbag program — not just bags for sale, but the expertise to get it right. 

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