October 26, 2026
Posted by: editor
Category: RECD & Emission Control Devices

A retrofit emission control device can leave one site looking immaculate and arrive at the next with a cracked substrate, a displaced element or a sheared sensor, and nobody will notice until the DG set is back under load and the numbers look wrong. If you need to transport an RECD, whether to send a core for cleaning, return a unit for refurbishment or move it along with a relocated generator, the risk sits almost entirely inside the casing.

The steel shell is the toughest part of the device. What gets hurt is everything it protects: ceramic or metallic substrates, catalyst coatings, the mats and seals that hold the element in position, and the sensors and controller some designs carry. They tolerate heat and engine vibration well, but not a sharp drop, a fork-tine point load or a week of trapped monsoon moisture.

This guide follows the RECD along its route, stage by stage, naming the hazard and the control at each step, then gives a damage-mode table, a transporter-ready packaging spec and an illustrative cost comparison.

Why RECD Internals Are More Fragile Than They Look

Before planning a move, it helps to understand which forces do the damage. If you want a refresher on what sits inside the casing, our explainer on how an RECD works and what its main parts do is a useful starting point, and DieselNet’s overview of diesel particulate filters explains the substrate types used in filter-based designs.

Shock, vibration, moisture and point loads are different threats

Shock is a short, sharp event: a drop from a tailboard, a hard forklift set-down, an unmarked speed breaker taken at speed. Ceramic substrates are brittle; a shock can start a crack that leaves no visible mark.
Vibration goes on for hours. It can loosen fasteners, fret the support mat and let an element creep in its can, especially if the mat is already aged by heat cycles.
Moisture comes from rain, condensation inside a wrap, or washing water left after cleaning. Soot and ash hold water; connectors and some coatings do not like it.
Point loads come from cargo stacked on top, a sling bearing on a sensor boss, or a fork tine against a thin panel.

How transit damage shows up later

The trouble with transit damage is that it is often delayed. A hairline crack in a wall-flow substrate may not leak much at first, then propagate after a few thermal cycles. Typical later symptoms include:

Loss of particulate capture, visible as higher smoke opacity or poorer test results, because exhaust finds a path through a crack.
Debris downstream, where fragments of substrate break away and appear at the outlet or in the stack.
Leakage around the element, if the element shifted and the mat or gasket no longer seals the annulus between element and can.
Abnormal pressure readings, either suspiciously low (bypass through damage) or high (crushed channels or debris blocking flow). Our post on how exhaust backpressure affects a DG set covers why that matters.
Sensor faults or open circuits from crushed sensor bodies, bent tubes or pulled connectors.
Corrosion or coating problems traced back to water that sat inside the unit for days.

Each of these can become a dispute over whether the engine, installer, transporter or product is at fault. Good packaging and records settle it.

Stage 1: Preparing the RECD at the Origin

Most transit damage is decided before the truck arrives. The origin site is where you control the condition of the unit, the parts that come off, and the evidence trail.

Let it cool, then isolate the DG set

A large insulated housing holds heat for hours. Let it cool to a safe handling temperature and verify with a thermometer, not by touch.

If the RECD is being removed from an installed DG set, treat it as maintenance work on energised equipment. Isolate the engine start circuit, the controller supply and any heater or auxiliary supply, and apply lockout/tagout before anyone unbolts flanges. The OSHA guidance on controlling hazardous energy is a widely used reference for the principles; follow your own site safety procedure and permit-to-work system.

Remove and pack sensors, controller and loose parts separately

If your RECD has pressure or temperature sensors, sampling tubes or a separate controller, remove them before the body is moved unless the supplier instructs otherwise. They are easy to snap.

Label each sensor and cable with its position and tag number.
Cap bosses with metal plugs, not tape.
Pack sensors in a foam-lined carton, sealed with desiccant.
Photograph connectors before disconnection.

If the sensors are being replaced rather than reused, read our guide on specifying replacement RECD sensors without losing compatibility before ordering.

Cap every opening

Close inlet and outlet flanges with bolted blanking plates over a gasket or foam layer; plastic sheet tied with rope is not a cap. Close drains, sampling ports and tappings too.

Document condition, serials and contents

Before wrapping, take a clear photo set:

All sides, nameplate, serial numbers and any element batch mark.
Inlet and outlet faces, showing the substrate where accessible.
Sensors and controller with tags visible.
Existing dents or corrosion, so they are not later blamed on the transporter.

Record dates in an unambiguous format such as the ISO 8601 date format (2026-10-17), note the last recorded pressure readings and running hours if available, and prepare a packing list that matches the photos. If the unit is being relocated with its generator, check the questions in our post on whether an RECD can be transferred to another diesel generator before you commit to the move.

Stage 2: The Packaging You Need to Transport an RECD Safely

Packaging is where most owners under-spend. The right spec depends on what is being moved, how far, and how many times it will be handled.

Crate or skid?

Situation	Suggested packaging
Complete assembly, short local move in a closed vehicle	Timber skid with blocking, full weatherproof wrap, top cover
Complete assembly, long route or transhipments	Closed timber crate on a skid base
Removable filter core sent for cleaning or refurbishment	Closed crate or returnable case, element supported along its full length
Sensors and controller	Foam-lined carton, inside the main crate or shipped separately
Export shipment	Crate in wood treated and marked per ISPM 15

Whether you should be moving a core or a full assembly in the first place is a separate decision, covered in our comparison of replacing an RECD filter core vs the complete assembly.

Cushioning, blocking and bracing

Cushioning absorbs shock; blocking and bracing stop movement. You need both.

Rest the unit on its designed support feet or saddles, not on its shell midspan or on flanges.
Use timber blocks or chocks against the support points, bolted or screwed into the skid, so the unit cannot slide in any direction.
For loose filter elements, support the element evenly along its length with shaped foam or cradles. Do not let it rest on its face or an edge.
Fill voids in the crate so nothing can move if the crate is tipped.
Strap the unit to the skid with ratchet straps over padded edges, never over sensor bosses or thin covers.

Orientation

Ask the supplier which way the unit should travel. Many housings and elements are designed to be supported in their installed orientation, and some designs should not be laid on their side. Mark the required orientation clearly and repeat it on the delivery note.

Centre of gravity and lifting marks

An RECD with a heavy element at one end and an empty inlet cone at the other can have its centre of gravity well off the geometric centre. Mark the centre of gravity on at least two faces of the crate, mark the lifting and fork entry points, and state the gross weight. Riggers will use what you give them; if you give them nothing they will guess.

Moisture barrier and desiccant

For anything longer than a same-day dry-weather trip, or any monsoon-season move:

Wrap the unit in heavy barrier film, sealed at seams.
Add desiccant sized to the enclosed volume.
Add a humidity indicator card behind a visible window.
Ensure a cleaned core is fully dry first; sealing in water is worse than not sealing.

The same principles apply when the unit will wait at the destination; our sibling guide on how to store an RECD before it is installed picks up where transit ends, and protecting an RECD from rainwater and condensation covers the installed case.

Labels

Use durable printed labels on at least two sides: “this way up” arrows, “fragile”, “do not stack”, “keep dry”, plus gross weight and a consignee contact number.

Validating a packaging design

If you move cores regularly between sites, have the crate design validated. The ISTA test procedures are a common reference for testing packages against drops, vibration and compression; ask your packaging vendor which procedure, if any, their design was tested to. For export consignments, the ISPM 15 wood packaging standard published by the IPPC governs treatment and marking of wooden packaging; it is not a requirement for domestic Indian road moves.

Stage 3: Loading — RECD Lifting and Loading Without Point Loads

Loading is the second most common damage point after unloading. The hazards are drops, swinging loads and lifting from the wrong place.

Choose the right equipment

Use a forklift whose forks span the skid fully, or a crane or hydra with a competent rigger.
Check rated capacity at the actual reach, not the headline figure.

Lift only from designed points

Lift by the skid, crate base or the manufacturer’s lugs. Never lift by the inlet or outlet pipe, sensor bosses, insulation cladding or the controller bracket. A sling around the shell can crush thin sheet. Use spreader beams where the lifting lugs are not vertically above the centre of gravity.

Control the load

Use tag lines to stop the load rotating. Lower slowly onto the vehicle bed. Keep people out from under the suspended load at all times, and stop work if wind or rain makes control difficult.

Stage 4: On the Road — Indian Conditions

This is the stage owners see least, and where transit damage to RECD substrates often begins: potholes, unmarked speed breakers, rough diversions and open trucks in heavy rain.

Vehicle choice

Prefer a closed body vehicle for anything beyond a short local move, and always in the monsoon.
If only an open truck is available, add a tarpaulin secured so it cannot flap, over the barrier wrap.
Choose a bed long enough that the crate does not overhang the tailboard.
For high-value cores on long routes, ask whether an air-suspension vehicle is available.

Tie-down method

Position the crate over the axles, not at the extreme rear.
Use rated ratchet straps to proper tie-down points, with edge protectors at corners.
Block the skid so it cannot slide forward under braking.
Recheck strap tension after the first few kilometres and at each stop.

No loose cargo on top

The commonest abuse of a well-packed RECD is other cargo loaded on top. Put “do not stack” in the contract and LR (lorry receipt) instructions, not just on the label, and for part loads ask for it to be loaded last and unloaded first.

Route and driving

Ask the driver to avoid known bad stretches and slow right down for speed breakers; a slower trip is cheaper than a cracked substrate.

Shock and tilt indicators

Low-cost single-use shock and tilt indicators stuck on the crate show whether the load was dropped or tipped beyond a threshold, and visibly fitted indicators tend to improve handling. Photograph them with serials at dispatch.

Stage 5: Unloading and Site Movement

The last hundred metres often carry more risk than the previous hundred kilometres. Many Indian DG rooms are in basements, on rooftops or behind narrow service corridors.

Plan the path before the truck arrives

Walk the route with a tape measure: door widths, ramp gradients, corridor turns, floor loading.
Confirm whether the crate fits or must be uncrated at the gate.
Arrange skates, pallet trucks or chain blocks in advance.

Our guides on basement DG room space and access planning and rooftop RECD installation, structural support and lifting access go into the site-specific detail.

Stairs, ramps and rooftops

Never manhandle a core down stairs; use a stair-climbing trolley or crane it in.
Keep the stated orientation throughout.
For rooftop lifts, use a lifting plan, exclusion zone and competent rigger, never in high wind.

If you have to uncrate early

If the crate will not fit, uncrate in a dry, covered area, keep the barrier wrap on, and move the unit on its skid. Re-cover it as soon as it is in position.

Stage 6: Receiving Inspection and Documenting Damage

Receipt is where your evidence is either created or lost. Once the transporter has left with a clean signature, it becomes much harder to show where damage happened. Our RECD delivery inspection checklist covers new supplies; the steps below focus on what matters for a returning or relocated unit.

Before opening

Photograph the vehicle, the load as it sits, and the crate from all sides before unloading.
Check shock and tilt indicators and photograph them with their serials.
Look for crushed corners, broken battens, torn wrap, water stains or signs of stacking.
Check the humidity indicator card through its window, if fitted.

On the delivery documents

If anything looks wrong, write a specific remark on the delivery challan and LR before signing: for example “crate corner crushed, tilt indicator activated, contents not yet inspected”. “Received subject to inspection” alone may carry little weight. Get the driver’s name and vehicle number.

Opening and inspecting

Open the crate carefully, photographing each layer, and compare with the origin photo set.
Inspect substrate faces with a torch for cracks, chips or displacement, and check for gaps at the element seal.
If you hear loose debris when moving the unit gently, stop and record it.
Check sensors for bent tubes and damaged connectors.

Reporting

Notify the transporter and your insurer in writing as soon as damage is found, within the time limits set in your transport contract and insurance policy. Those limits vary and can be short, so read them before the shipment, not after. Inform the RECD supplier too, as they may need to inspect before any repair. Our sibling post on what to record when raising an RECD warranty claim explains how to build an evidence file that suppliers and insurers can act on.

RECD Transit Damage Modes at a Glance

Damage	Typical cause in transit	How to detect at receipt	Consequence if missed
Cracked ceramic substrate	Drop, hard set-down, speed breaker shock	Torch inspection of faces, shock indicator activated, fragments in packaging	Loss of PM capture, debris downstream, failed tests
Element shifted in housing	Unsupported element, wrong orientation, prolonged vibration	Misaligned face, gap at seal, element not flush	Exhaust leakage around element, poor efficiency
Damaged support mat or seal	Vibration with loose blocking, element creep	Visible mat at edges, looseness, seal compression marks	Further shifting and bypass after a few heat cycles
Crushed or bent sensor	Sensor left fitted, sling or cargo bearing on boss	Visual check, continuity test	Wrong pressure or temperature readings, controller alarms
Moisture ingress	Open truck in rain, unsealed openings, wet core wrapped	Humidity card, water marks, damp wrap	Corrosion, connector faults, wet soot and ash deposits
Dented casing or flange	Fork tine contact, stacking, impact	Visual and straight-edge check of flange faces	Gasket leaks at installation, misalignment
Missing loose parts	Unsecured cartons, no packing list	Check against packing list and photos	Installation delay, mismatched replacements

A Packaging Specification You Can Hand to a Transporter

Copy this checklist into your work order or transport instruction. Adapt it for your unit and get the supplier to confirm any orientation or support requirements.

Consignment: assembly or core, serial number, gross weight, crate dimensions.
Packaging: closed crate on skid base; unit on its own feet or saddles; loose element supported along its full length.
Blocking: timber blocks fixed on all sides; padded straps, never over sensors, flanges or covers.
Openings: inlet, outlet, ports and drains closed with rigid blanking covers.
Detachable parts: sensors, controller and cables removed, labelled and packed in a separate foam-lined carton, listed on the packing list.
Moisture: sealed barrier wrap, desiccant, humidity indicator card.
Indicators: shock and tilt indicators fixed and photographed at dispatch.
Marking: orientation, fragile, do not stack, keep dry, centre of gravity, lifting points, weight, contact.
Vehicle: closed body for rain or long routes; no overhang.
Loading: forklift or crane from skid or designated lugs only; tag lines; no lifting by pipes or bosses.
Securing: crate over axles where possible; rated ratchet straps to vehicle anchor points; edge protectors.
Prohibitions: no cargo on top; no transhipment without notice; no uncrating by transporter.
Driving: reduced speed over speed breakers and broken surfaces; strap check after first few kilometres.
Receipt: consignee to photograph before unloading and note any visible damage on LR before signing.

Insurance and Responsibility: Who Bears the Risk?

Who owns transit risk depends on your purchase order, service contract, transport contract and insurance, and differs between a new supply, a warranty return and a paid refurbishment.

Questions to settle before dispatch

Who arranges transport? If the supplier collects a core, their terms may apply; if you send it, yours do.
When does risk pass? Contracts often fix this with Incoterms-style delivery terms, such as at dispatch or on delivery. Check your documents rather than assuming.
Is it insured, and for what value? Transit policies often pay declared value only, so an under-declared core is compensated at that low figure.
Does the policy expect adequate packaging? Claims can be disputed where packaging was clearly poor; your packing photos are your answer.
What does the warranty say? Warranties commonly exclude damage from handling or transport by others. Read the exclusions; our post on RECD warranty terms, parts, labour and exclusions explains what to look for.

The split of duties between owner, installer and supplier is easier to manage if it is written into the project scope from the start; see our note on customer and installer responsibilities in an RECD project.

For the precise legal position on carrier liability, consult your legal or insurance adviser, though contract and policy wording usually decides the outcome.

Illustrative Example: Sending a Filter Core from Noida for Cleaning

Illustrative only. Figures are assumptions chosen to show the arithmetic, not quotations.

A facility in Noida needs to send the removable filter core from its RECD to a service workshop about 40 km away for cleaning, and bring it back. The team compares a “cheap” move (core wrapped in sheet, strapped on an open pickup) with a protected move.

Cost of the protected move

Item	Basis	Cost
Reusable timber crate with shaped supports	One crate, used both ways	₹14,000
Barrier wrap, desiccant, humidity card	₹2,500 per leg × 2 legs	₹5,000
Shock and tilt indicators	₹1,200 per leg × 2 legs	₹2,400
Closed-body vehicle premium over open pickup	₹6,000 per leg × 2 legs	₹12,000
Total extra spend	₹14,000 + ₹5,000 + ₹2,400 + ₹12,000	₹33,400

Cost if the core is damaged

Item	Cost
Replacement filter core (assumed)	₹3,20,000
Re-installation and re-test	₹25,000
Total	₹3,45,000

That excludes downtime, compliance exposure if the DG set cannot run with a working RECD, and time spent on a disputed claim.

Break-even

The protective spend pays for itself if the chance of damaging the core on an unprotected round trip is higher than:

₹33,400 ÷ ₹3,45,000 = 0.0968, or about 9.7%.

Given Delhi NCR roads, open pickups in mixed weather and at least four handling events (load and unload at each end), most engineers would put the unprotected risk well above one in ten. The crate is also reusable for the next cleaning cycle, so on the second round trip the extra spend falls to ₹33,400 − ₹14,000 = ₹19,400, and the break-even drops to ₹19,400 ÷ ₹3,45,000 = 0.0562, or about 5.6%.

If the core is damaged anyway, the photos, indicators and LR remark give a far stronger basis for a claim. Before a refurbished core goes back into service, read our sibling guide on whether a refurbished RECD filter core can be reused, and keep the cleaning records alongside your routine RECD maintenance records.

FAQ

Can I transport an RECD with its sensors still fitted?

Remove them, cap the bosses and pack them separately unless your supplier says otherwise; fitted sensors are easily sheared.

Does an RECD need to travel in a particular orientation?

Often, yes. Many housings and elements are designed to be supported in their installed orientation. Ask your supplier, then mark the orientation on the crate and the delivery note.

Is an open truck acceptable for moving an RECD between sites?

Only for short, dry-weather moves with a full weatherproof wrap and cover. For long routes, monsoon moves or loose filter cores, use a closed-body vehicle.

How can I tell if a filter substrate cracked in transit?

Check indicators, inspect faces with a torch and compare with origin photos. Some cracks only show later, so retest after reinstallation.

Do I need ISPM 15 treated wood for domestic shipments?

ISPM 15 applies to wooden packaging in international trade. For domestic road moves within India it is generally not needed, but confirm if the crate may later be used for export.

How quickly must I report transit damage?

Report in writing as soon as you find it, within the time limits in your transport contract and insurance policy. Read those limits before the shipment, since they can be short.

Planning a Move or a Core Service? Talk to Aceget First

Before you crate anything, a short call with the supplier can save a damaged core. Aceget supplies CPCB type-approved retrofit emission control devices for DG sets from 25 kVA to 2500 kVA and can advise on handling, orientation and returns for your installed unit. You can review our type approvals and certifications, or contact the Aceget team with your unit’s serial number and planned route.

How to Package and Transport an RECD Without Damaging Its Internals