When a production team ships a wall of large-format screens across three states for a corporate keynote, the install rarely fails on stage. It fails in the truck. Vibration, stacking, forklift handling, and the simple physics of moving 60-inch panels are where displays crack, bezels chip, and a six-figure AV build turns into an insurance claim. The crew behind this particular multi-display install knew that, which is why they treated their flat screen cases as the most important purchase of the entire project, not an afterthought bolted on at the end. The result was a wall of screens that arrived, unpacked, and powered up exactly as designed, with no scratches, no stress fractures, and no scramble for replacements the night before doors. This is how they planned it, and what other AV teams can learn from a build that survived the road intact.

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The Real Risk Lives in Transit, Not On Site

Most AV failures get blamed on the venue, but the damage usually happens long before anyone reaches the loading dock. A flat panel is engineered to hang flat and stay still. The moment it goes horizontal, gets stacked, and rides a few hundred miles of highway, it experiences forces it was never built to absorb. Corners take point loads. Screens flex under the weight of whatever sits on top. Loose accessories rattle against glass for hours. By the time the truck arrives, a panel can look fine and still carry hairline damage that only shows up when it is powered on under stage lighting. The team on this install understood that protecting the screens in transit was not about wrapping them in blankets and hoping. It was about removing the variables entirely so that handling mistakes, which are inevitable on a busy dock, simply did not reach the glass.

Why Standard Packing Fails Multi-Display Builds

Cardboard cartons and reusable shipping foam are designed for a single trip from factory to buyer. They are not designed to be loaded, unloaded, and reloaded dozens of times across a tour or an event season. After two or three handling cycles, factory packaging compresses, tears, and stops holding the screen in place. Multi-display builds make this worse because the panels are often near-identical, get stacked to save truck space, and need to come out fast and go back in faster during a tight strike. The crew avoided all of it by speccing purpose-built ATA cases from Gravix, where each case was engineered around the panel rather than the panel being forced into a generic box. Cases that latch, seal, and stack predictably turned a chaotic load-out into a repeatable one, which is the entire point when a schedule leaves no room for damage or delay.

Building the Case Plan Around the Screens

The planning started with a spreadsheet of every display going on the truck: dimensions, weight, mounting hardware, and how often each unit would be handled. That inventory drove the case decisions. Heavier large-format panels that needed to be raised into position got cases with integrated lifting support, drawn from the Electric Power Lift Cases range, so crew members were not manually hoisting awkward weight at height. Standard panels went into right-sized protective cases matched to their exact footprint. Nothing shared a case with gear that could shift and strike it. By mapping the case plan to the actual build instead of buying generic sizes and improvising, the team eliminated the guesswork that usually leads to a panel riding loose or a case that almost fits but not quite.

Not sure which case size or configuration your displays actually need? Gravix works directly with AV and production teams to match cases to real equipment dimensions and handling demands, so you order once and order right. Talk through your build with a specialist before you commit. → Gravix

Matching the Case to the Screen Size

Sizing is where flat panel protection succeeds or fails. A case that is even slightly too large lets the screen move, and movement under vibration is what cracks glass. A case that is too tight stresses the bezel every time it goes in or out. The team pulled their cases from the full Flat Screen Cases catalogue, choosing the exact size bracket for each panel rather than rounding up to a one-size box. For the bulk of the wall, which ran in the popular mid-to-large range, the Large Screens 51-60 cases gave a precise fit with custom foam holding each unit suspended away from the case walls. That suspension is the quiet hero of any clean delivery: the screen never touches a hard surface, so impacts that reach the case shell dissipate before they reach the glass. Right-sizing every case is unglamorous work, but it is the single biggest reason this install arrived without a mark.

What "Shipped Without a Scratch" Actually Requires

A flawless delivery is not luck. It is the sum of several deliberate choices working together. The cases were sealed against dust and moisture, so a rained-on dock did not become a problem. The ABS-laminated walls and hard-seal interiors absorbed the knocks that come with forklifts and tight truck packs. Recessed latches and reinforced corners survived being stacked and dragged. And because the cases were built in the USA to ATA-style standards rather than sourced as the cheapest available option, they held their shape through repeated handling instead of degrading after the first trip. None of these features draws attention on their own. Together, they are the difference between unpacking a ready-to-run screen wall and discovering a cracked panel an hour before the client walks in. For this crew, paying for protection up front was far cheaper than the cost of a single failed display and a delayed show.

Frequently Asked Questions

Why not just use the original packaging the displays shipped in? 

Factory packaging is built for one trip and one handling cycle. It compresses, tears, and loses its grip on the screen after repeated loading and unloading, which is exactly what happens on a tour or multi-venue event. Purpose-built ATA cases are engineered to be handled hundreds of times, hold the panel securely each trip, and stack predictably in a truck. For any display that moves more than once, reusable hard cases protect the investment far better than the box it arrived in.

How important is getting the exact case size for a flat panel?

It is the most important factor. A case that is too large lets the screen shift under vibration, and that movement is the leading cause of cracked glass in transit. A case that is too tight stresses the bezel during loading. Matching the case to the precise screen dimensions, with foam that suspends the panel away from the walls, keeps the display still and isolated from impact. Right-sizing is the difference between protection and false confidence.

Do larger displays need different handling than smaller ones? 

Yes. Bigger panels are heavier, more awkward, and more dangerous to lift into position, especially at height. Cases with integrated electric lift support let crews raise heavy displays safely instead of manually hoisting them, which protects both the gear and the people moving it. Larger screens also benefit from reinforced construction and more robust foam, since they carry more momentum and more value if something goes wrong.

Are custom cases worth it for a one-time install? 

Often, yes, because a single damaged large-format display usually costs more than outfitting the whole build with proper cases. Even for a one-time install, the gear typically travels to the venue, gets staged, and travels back, which is several handling cycles. Custom cases also retain value as reusable inventory for future projects, so the spend is rarely a one-and-done cost. Weigh the case price against the replacement cost and lost time of a cracked screen, and the math is usually clear.

Conclusion

The reason this multi-display wall shipped without a scratch is almost boring in its simplicity: the team treated transit protection as a design problem, not a packing chore. They inventoried every screen, matched each one to a precisely sized case, used lift-equipped cases for the heavy units, and refused to let any panel ride loose or share space with gear that could strike it. The cases did the rest, absorbing the forklifts, the stacking, and the miles so the glass never had to. For any AV crew that has ever opened a road case to find a cracked display, the lesson is straightforward. Protection planned around your actual equipment, in cases built to survive real handling, is what turns a nerve-wracking load-out into a delivery you never have to think about again.

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