Common Mistakes in Dunnage Airbag Installation and How to Avoid Them

Improper use of dunnage airbags causes more damage than most teams realize. Surprisingly, these inflatable dunnage airbags can cause huge damage when people do not use them right. They’re supposed to keep your cargo from bouncing around during freight transport, but if it is pushed one in a half-inflated, sets it in the wrong place, or goes overboard and sets it up too tight, they don’t do their job. Loads move, products break, and customers complain. That’s not just a packaging error; it’s a serious load securement issue.    

Even though air dunnage bags are easy to find and simple to use, mistakes still happen. People skip instructions. They guess the inflation level. They place bags where they don’t belong. It’s not just a packaging engineering issue; it’s a supply chain risk.

This blog covers the most common mistakes people make when installing dunnage bags and how to fix them.

What Are Dunnage Airbags and Why Do They Matter 

Purpose and Function  

Air dunnage bags are inflatable cushions used to keep cargo from shifting during transport. They fill gaps between pallets or containers and hold everything in place. When used right, they reduce damage and help shipments arrive safely.

There are different types:

• Poly woven dunnage bags are strong and resist moisture. Good for heavy loads.
• Kraft dunnage air bags are budget-friendly and easy to dispose of.

You’ll find these in trucks and railcars. They’re also used in shipping containers. They are part of everyday freight transport. And they matter because poor load securement leads to broken products, delays, and extra costs.

If you’re in packaging engineering or logistics, it’s worth getting the basics right. A well-placed airbag can save a lot of trouble down the line.  

For a deeper dive into the types, uses, and benefits of these protective packaging tools, check out our Ultimate Guide to Dunnage Bags

Industry Standards and Compliance  

Dunnage bags aren’t just helpful, they’re regulated. To work safely, they need to meet specific standards.

• AAR (Association of American Railroads) sets rules for rail transport. Bags must pass strength and durability tests.
• ASTM (American Society for Testing and Materials) sets testing methods for materials and valves. It also defines how to measure burst pressure.
• ISO (International Organization for Standardization) sets global rules to ensure products are safe and work well everywhere. 

Why It Matters: Air dunnage bag manufacturers test each airbag and add the right label before it’s used. A good supplier will follow these standards and share the documentation. That’s how you know the product is reliable.

Inflation Protocols: Each bag has a recommended PSI. If the bag has too little air, it won’t support the load. If it has too much, it could burst. Use the right tools. Follow the instructions. Don’t guess.

Getting this wrong isn’t just a packaging issue; it’s a compliance risk. And it can cost you.

For a deeper look at why AAR verification is critical specifically for rail shipments, check out our blog: Why Rail Shipments Require AAR-Verified Dunnage Air Bags

Common Mistakes in Dunnage Airbag Installation

Incorrect Sizing

Some teams use bags that don’t fit the gap.

• A small bag moves around and doesn’t support the load. 
• A big bag pushes too hard and can damage the cargo.

Result: The cargo moves. The pressure isn’t balanced. Things break.

Over- or Under-Inflation

Bags need the right amount of air. 

• Too much, and they burst.
• Too little, and they collapse.

Why it happens: No pressure gauge. No training. Just guessing.

Result: The bag fails. The load shifts.

Poor Placement  

Bags must sit flat between pallets.

• If they’re crooked or pressed against sharp edges, they tear.
• If there’s no bracing above or below, the load can move up or down.

Result: The bag doesn’t protect the cargo. It becomes a weak point.

Ignoring Environmental Factors

Poly woven dunnage bags react to heat and moisture.

• In hot weather, they stretch.
• In damp conditions, they weaken.

Other risks: Using old or damaged shipping airbags. Using bags stored in bad conditions.

Result: The bag loses strength. It doesn’t hold pressure.

According to TT Club, two-thirds of cargo damage claims are caused or made worse by poor packing practices, which include incorrect load securing, improper use of dunnage, and lack of training. While the exact “30%” figure isn’t cited directly, this source supports the broader point: improper dunnage installation is a major contributor to in-transit damage.

Side-by-side comparison of correct vs. incorrect air dunnage bag installation

How to Avoid These Mistakes

Simple Guide to Install Dunnage Bags Step by Step

Training & SOPs

Why It Matters 

Cargo often gets damaged because people miss steps or don’t know what to check. That’s why training and clear instructions matter. They’re the difference between a secure load and a costly mistake.

Staff Training

• Teach teams how to measure voids, choose the right bag, and inflate correctly.
• Use real examples, not just theory.
• Make sure everyone knows what “good” looks like and what to avoid.

Visual SOPs

• Use photos, diagrams, and short checklists.
• Keep them posted near loading zones.
• Make it easy for new staff and non-native speakers to understand.

Partner Support

• Partner with reliable air dunnage bag manufacturers.
• Get product demos and hands-on training.
• Use their knowledge to fix mistakes and improve your process.

Need a step-by-step guide for proper use? Explore our blog: Dunnage Air Bag Best Practices: A Step‑by‑Step Cargo Securement Guide for practical tips your team can follow

Quality Control & Inspection for Inflatable Dunnage Air Bags

Checklist before shipping 

Before closing the container or truck, check these points:

• Bag size matches the void space
• Bag type suits the load weight and transport mode
• Inflation pressure is within the recommended PSI range
• The bag is centered and stable between pallets
• No sharp edges or uneven gaps nearby
• Edge protectors and bracing are in place
• The bag shows no signs of damage, wear, or leaks
• Valve is sealed and secure
• The load is locked in place, no shifting when nudged

When to Replace or Retire 

Replace the bag if:

• It looks stretched, torn, or punctured
• The valve is cracked, loose, or leaking
• The seams are frayed or separating
• It no longer holds pressure during inflation
• It’s been reused beyond the manufacturer’s limit
• It was exposed to moisture, heat, or chemicals during storage

Choosing the Right Dunnage Airbags for Your Needs 

Material Comparison

Choose based on load weight, trip length, and whether reuse is needed.

Sourcing Smart

How to Evaluate Dunnage Bags for Sale Online

• Check product specs: size, burst pressure, material type
• Look for certifications like AAR, ISO, or SGS when selecting shipping airbags
• Avoid listings with vague descriptions or missing ratings
• Read reviews from verified buyers
• Compare warranty and return policies

Vendor Support & Customization

Why Partnerships with Air Dunnage Bag Manufacturers Help

• Get expert advice on bag selection and placement
• Ask for product demos or staff training
• Request custom sizes for unusual gaps
• Explore branding options like logo printing or color coding
• Build long-term support for bulk orders and replacements

Table comparing types of dunnage airbags by material, cost, and use case

Conclusion

Installing dunnage airbags properly isn’t just a technical step. It’s a business decision. When dunnage bags are of the proper size and placed correctly, they hold the load in place. That means less cargo damage and fewer claims. And your customers stay satisfied.

The return is clear:  less damage and better delivery results. It also makes compliance easier and more consistent. It only works when your team knows what to do and your suppliers understand your needs. So pick the right products and train your team to use them right. Choose certified products. Work with vendors who offer support. And make sure your SOPs are easy to follow.

If you’re looking at options, Dunnage Systems Inc. is a good place to begin. They offer certified airbags, help with sizing, and support for training and placement. No fluff, just the tools and guidance to get it right.