How to Use Strapping: Handling Steel, Plastic, & PP Strap

Strapping is the backbone of safe and efficient logistics operations. Whether you're securing pallets for transportation or bundling items for storage, strapping ensures that your goods stay intact and protected. Using strapping effectively requires the right knowledge and tools, as missteps can lead to loose cargo, damaged products, and even safety hazards.

This guide will teach you how to use handheld tools and strap loads with  steel strapping, plastic strapping, or polypropylene strapping . Find the step-by-step instructions and expert tips to streamline your operations below.

Why Strapping Is Important For Securing Cargo?

Strapping is essential for keeping goods stable during transportation and storage. Without proper strapping, cargo can shift, leading to damaged products, unsafe working conditions, and costly returns. Effective strapping mitigates these risks by holding items firmly in place, preventing movement even during rough handling or long haul journeys.

Beyond safety, strapping also optimises your operations. It simplifies handling, reduces packaging waste, and increases efficiency. With several types of strapping available, it’s vital to know how to handle each one correctly to maximise these benefits.

How To Use Steel Strapping with Manual Handheld Tools

Steel Strapping has been a trusted solution for decades, known for its unmatched strength and durability. It’s ideal for securing heavy loads like pipes, tubing, and temperature-sensitive products that radiate heat.

Step 1: Prepare Your Strapping Tools & Strap

Before you begin, gather the necessary tools, such as a strapping tensioner and strapping sealer tool, or you may have a manual combination tool (tensioner & sealer in one tool). 

1. Wrap the steel strap around the item ensuring the strap closest to your body is on the bottom, with the other end on top.
2. If you are using a full overlap seal you will need to slide it on during this step
3. Pull the strapping to remove any slack

Step 2: Use the Tensioner: Tension the strap

1. Hold the tool in your dominant hand
2. Overlap both straps under the tension wheel and through the device. Leave about 10cm of overlapping strap at the front of the tool
3. Release the tension lever
4. Begin moving the tension lever back and forth, stopping when getting to desired level
5. Once fully tensioned if the handle is in the forward position, you will need to reposition it. Push the release lever at the front of the tension lever and this will allow the handle to fall back down to the start position

Step 3: Put the seal in place & use the Sealer

1. To seal place your seal open side down, over where the strap overlaps in front of the tensioning tool
2. Completely close the nose of the sealer around the seal and crimp tightly around the strapping 
3. Remove the sealing tool. To remove the tensioning tool, squeeze the base handle and tension lever together to release the tension and move the tool to the side to remove the strap

Step 4: Cut Off Any Excess Strap

1. Cut off the excess strap with heavy duty cutters. Some sealing tools have integrated cutters, if so use this tool to complete the strapping cycle
2. Be mindful that tense steel strap can snap back when cut. Ensure the area is clear of hazards and you are wearing protective gloves and goggles.

How to Use Plastic Strapping

Plastic (PET) strapping is a versatile and lightweight option suitable for securing cartons, pallets, and other loads. Its flexibility makes it a popular choice across industries.

Step 1: Prepare Your Strapping Tools

Before you begin, gather the necessary tools, such as a strapping tensioner and strapping sealer tool, or you may have a semi-automatic handheld battery strapping tool (tensions, seals and cuts in one tool). 

1. Wrap the PET strap around the item ensuring the strap closest to your body is on the bottom, with the other end on top.
2. If you are using a full overlap seal you will need to slide it on during this step. For semi-automatic battery strapping tools you will not need a metal seal.
3. Pull the strapping tight to remove any slack

Step 2: Use the PET Tensioner & tension the strap

For Manual Strapping Tools

1. Hold the tool in your dominant hand
2. Overlap both straps under the tension wheel and through the device. Leave about 10cm of overlapping strap at the front of the tool
3. Release the tension lever
4. Begin moving the tension lever back and forth, stopping when getting to desired level
5. Once fully tensioned if the handle is in the forward position, you will need to reposition it. Push the release lever at the front of the tension lever and this will allow the handle to fall back down to the start position

For Semi Automatic Handheld Battery Strapping Tools

1. Hold the tool in your dominant hand
2. Slide both straps into the guide on the side of the tool
3. Press the tension button lever on the tool
4. Once you feel the strap stop tensioning push down on the 2nd lever (or button) which will seal the strap by friction weld and cut the remaining strap
5. Move the tool to the side to release the strap and you are done - no further steps!

Step 3: Put the seal in place and use the PET sealing tool

1. To seal place your seal open side down, over where the strap overlaps in front of the tensioning tool
2. Completely close the nose of the sealer around the seal and crimp tightly around the strapping 
3. Remove the sealing tool. To remove the tensioning tool, squeeze the base handle and tension lever together to release the tension and move the tool to the side to remove the strap

Step 4: Cut Off Any Excess Strap

Trim the excess plastic strap to prevent overhang, which could pose a safety hazard. Keep your workspace tidy by disposing of the cut strap. PET strapping is 100% recyclable and can be placed in regular recycling bins.

How to Use Polypropylene (PP) Strapping

Polypropylene strapping is a cost effective solution for light duty applications. It’s best for securing small boxes, cartons, and light pallets.

Step 1: Prepare Your Strapping Tools

Gather the appropriate tools, including a PP manual strapping tensioner and strap sealer, along with polypropylene strap and metal seals or buckles. Check the strap's specifications to ensure compatibility with your load.

Following Steps: With PP Manual Tensioner & Sealer

If you are completing the process with a manual tensioner and sealer with metal seals, you can complete the same process as the PET strapping process above. However be sure to not over tension PP strap as it lacks elasticity and will not contract back onto the load, it will stretch. 

Steps when using a PP Tensioner and Metal Buckles: Tension & Buckle strap

1. Wrap the strap around the load
2. Loop one end of the strap through the buckle and around an open leg to form a loop
3. Make sure the strap on the top of the loop is the shorter end
4. Repeat with the other end, creating tension by pulling the strapping tight by hand OR use the manual tensioning tool. If you are using a PP strap tensioner, pump the lever up and down until you reach the desired tension

Step 4: Cut Off Any Excess Strap

Cut off the excess PP strap neatly, ensuring there are no loose ends. This improves the presentation and safety of your packaging.

Tips for Effective Strapping

Invest in a strapping machine that aligns with your operation’s demands

For handheld strapping applications choosing between a manual strapping tools, a manual combination strapping tools, or semi automatic handheld battery strapping tools depends on your load volume and operational requirements.

Measure your pallets before strapping to reduce waste

Accurate measurements ensure you use the right amount of strap, minimising material waste and saving costs.

Ensure that your chosen strap material can handle the package you’re securing

From lightweight plastic strapping to heavy duty steel strapping, select the material that best suits your cargo’s weight and stability needs.

Identify the stress points of your cargo

Position straps at critical stress points to maximise load stability during transit.

Make strapping easy with FROMM Packaging Australia

FROMM Packaging Australia delivers complete strapping solutions for every challenge. From lightweight cartons secured with polypropylene to heavy loads stabilised with steel strapping, we understand your unique requirements. Our advanced technology transforms your operations. Through cutting edge PP strapping machines and precision engineered manual tools, we ensure both safety and efficiency in every application.

Ready to elevate your strapping game? Explore our range of products, including plastic strapping, and let our experts guide you in choosing the best solution for your business.