Global News Lack of heavy-lift air freight capacity forces shift to ocean transport

A combination of strong heavy-lift and outsized cargo demand, tight air cargo capacity and surging air freight rates has led to a modal shift in shipments from air to multipurpose vessels (MPVs), carriers and brokers say.

Over the past two years, charter rates for aircraft specializing in heavy-lift and outsized cargo have surged more than 50% on strong demand and capacity shortages, Andriy Blagovisniy, global director of air chartering at LP Aero, part of Logistics Plus, told the Journal of Commerce.

This has pushed charter rates for the heavy-lift air industry workhorse Antonov An-124 to over $2 million for a flight from Asia to the US. Heavy-lift and project cargo customers charter the entire airplane on an aircraft, crew, maintenance and insurance (ACMI) basis, unlike general air freight which is charged per kilogram. Actual rates are dependent on the type of cargo, flight duration and route.

“Charter rates are high, but at the same time it cannot be said that they are not affordable,” Blagovisniy said. “When customers make the decision to use air transport their choice is always based on whether to gain time or save money given the significant financial losses that can arise from delays in delivery of project cargo.”

However, he said that strong demand has led to longer lead times for specialized air freight.

“To transport project cargo by air it is now necessary to book an aircraft approximately six to seven weeks in advance,” Blagovisniy said. That’s at least double the time needed two years ago.

Time also needs to be factored in for the bespoke preparations necessary for the carriage of project cargoes, including the design and manufacture of frames to hold the cargo and the provision of lashing and lifting points to ensure safe weight distribution in the aircraft.

The supply squeeze has meant that the waiting time for aircraft availability is now comparable with the time taken to deliver cargo by sea – though sea transportation is considerably cheaper, Blagovisniy said.

“Consequently, customers who previously traditionally considered air delivery as the fastest and most convenient option are now, from the very beginning, planning and building their logistics needs on the delivery of project cargo by ship,” Blagovisniy added. MPV carrier welcomes modal shift Blagovisniy’s comments were echoed by Marc Willim, general manager and head of chartering at MPV operator AAL Shipping.

“We have heard about such cases of heavy-lift air freight shipments moving to ocean freight from our forwarder clients,” Willim told the Journal of Commerce. “It is, however, difficult for us to quantify how many times or which cargoes specifically have shifted.

“Due to the typically urgent nature of these shipments, we have a policy of earliest possibly engagement and forward planning with our project customers…and we can plan and lock in sailings early to satisfy individual project or customer needs,” he added.

There are few aircraft capable of transporting heavy-lift or outsized project cargo loads. These include the AN-124, the world’s largest commercial cargo aircraft operated by Ukraine’s Antonov Airlines, Boeing 747-400s and Ilyushin IL-76s, all with a 50-ton payload. The Airbus Beluga ST, based on an Airbus A300, can carry up to 40 mt.

Due to the Russia-Ukraine war, only six AN-124 Ukraine-registered aircraft remain active in the global heavy-lift transportation market, but “two of these are dedicated to transporting arms and supplies to Ukraine,” a broker said.

Ongoing aircraft maintenance means that only two to four AN-124s currently operate on the global commercial market, said the broker, who did not want to be identified.

Volga-Dnepr Airlines, which claims to have a fleet of 10 AN-124s, only operates two aircraft because the rest are grounded due to Western sanctions imposed on Russia following its invasion of Ukraine. The two aircraft only operate between Russia and “friendly” countries including China, India and Kazakhstan. There are just two Ilyushin IL-76s available on the market today.

“Boeing 747s are more widely available, operated by cargo airlines including Cargolux and Kalitta Air, and have the flexibility to load project cargo through their nose door. But technically, they are more limited due to cargo door dimensions and maximum permissible floor loads,” the broker added. Shippers hold for Beluga capacity Tight specialized air freight capacity is expected to continue into next year. Benoît Lemonnier, Airbus Beluga Transport’s managing director, anticipates the situation will improve next year when the airline, specially created by European aircraft maker Airbus, starts to more actively promote its five Beluga Super Transporter (ST) aircraft.

The priorities for 2025 are Airbus-related cargoes including satellites and helicopters “and the upcoming transport of new payloads for external strategic customers,” Lemonnier told the Journal of Commerce. “Aeronautics, defense and space are the most active with Beluga at the moment.”

Airbus Beluga Transport, which received its air operator’s certificate in November 2023, has focused on developing its operations, flying around 700 hours in the first nine months of this year mainly on European and a few long-range flights, he said.

The Beluga ST has a 40 mt payload and the world’s largest interior cross-section of any transport aircraft, accommodating outsized cargo of up to 23 feet wide and 22 feet high.