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Start by classifying the move: oversize/overweight (OS/OW), trip/fuel (IRP/IFTA substitutes), or route-restricted/local (city, port, toll authority). Confirm the load is non-reducible, then measure overall dimensions, axle spacings, and weights. For each state on your route, apply through its DOT permit portal (many use systems like SUPERLOAD/CTPS/TXPROS) and request a single-trip or annual permit. Upload drawings if required; the state will issue a routing with conditions—escort cars, “OVERSIZE LOAD” signage, flags/lights, curfews/holiday bans, speed limits. If you’ll use municipal or county roads, obtain local permits as well. Carry permits in-cab and follow the assigned route exactly; request an amendment if the date, dimensions, power unit, or route changes.
Decide whether you need federal FMCSA Hazardous Materials Safety Permit (HMSP) (for high-risk classes like certain explosives, PIH gases/liquids, HRCQ radioactive, LNG/methane in bulk) and/or state hazmat permits (some states require separate credentials or route approvals/tunnel clearances). Federally, file via FMCSA (MCS-150B/URS) and maintain prerequisites: USDOT/MC active, required public-liability limits per 49 CFR Part 387, a CDL with H endorsement (and TSA Security Threat Assessment) for each driver, hazmat training under 49 CFR 172.704, security plan (49 CFR 172.800) and written emergency response procedures, plus PHMSA Hazardous Materials Registration (RIN) if applicable. For states, apply through each jurisdiction’s portal, submit vehicle/driver lists, insurance COIs, routes/commodities, and pay fees; expect conditions such as placarding, designated routes, escorts, curfews, and incident reporting. Keep all permits and response information in the cab and ensure your shipping papers and placards match the load at all times.