As a production manager, one of the primary responsibilities leading up to a tour is the allotment of trailer weight and space. It’s a major concern for van and bus trailers but applies to tractor trailers as well. I have this conversation with colleagues on a regular basis and I’d love to get a dialogue started to see how others approach the issues.

The problems I encounter with regard to trailers:

1. Weight. Regardless of how much you can physically fit into a trailer, there are weight limits set by the manufacturer for many reasons, primarily safety. To much weight can lead to broken leaf springs, blown tires, and failed axels or wheel bearings. All while going down the interstate at 70 miles an hour.
It's important to note that both the DOT and coach vendors are cracking down on these restrictions. Upon being loaded for the first time some drivers will head directly to a weigh station. If the trailer is overweight they will not pull it and you have to scramble for another option. Speaking from first-hand experience, this is a scenario you want to avoid.
If the driver is issued a ticket for an overweight trailer it may not reflect on you directly, but this is their lively hood and we owe them the respect of doing our due diligence to ensure the trailer is within the legal operating limits.

2. Space. A production in the midst of growth is a sure recipe for miscalculation. Any time we make the transition into a larger trailer, common sense takes a back seat to the excitement and we forget that more space doesn’t mean endless space. We still need to be mindful of what we’re carrying and reduce the load where possible.
Any small lighting package adds up quick. A few ground fixtures seem simple enough, but also consider cabling, a dimmer, feeder, and a console.
Same applies to audio. Carrying two consoles means a split snake, and while many new consoles can share preamps and use a cat5 or fiber snake, self-contained still means mics, cables, sub-snakes, and mic stands. The switch from wedges to in-ear monitors can make a substantial difference, leaving cases of wedges and heavy amp racks behind can be a game changer.
Truss seems simple enough and will fit in a trailer. Just remember to include it in your trailer pack. At the very least you’ll need some flat space to stack it, but I recommend requesting a trailer with vertical e-track so you can build a headache rack using load bars. This makes the space below the truss more manageable and accessible. Don’t forget to account for those awkward, heavy truss bases.

Merch is always an afterthought but I suggest you take it seriously. It’s easy to pass it off as “just some t-shirts”, but the weight adds up quick and the space required is substantial. Don’t forget the merch tote(s) (full of hangers, display lights, posters, etc), a cart of some sort to transport the merch, and those finger biting merch grids.  Don’t allow yourself to get caught in the “we can always throw some in a bus bay” mentality, that’s setting you up for failure. Bus bays are for luggage (and the occasional fold up bike), not gear or merch.

Lots to cover with this topic so at some point I’ll do a follow up to continue the discussion. I’ve had good experiences where my estimates pan out and everything fits and comes in underweight. And I've had some rough ones requiring a last minute scramble to hire a semi for the tour. Please drop a line in the comment section, interested to hear some feedback on how you plan a trailer pack.