Capacity Guidelines & Optimization

Maximizing freight capacity requires understanding weight limits, volume calculations, and optimization strategies. This guide provides comprehensive guidelines for efficient cargo planning and load optimization.

Weight LimitsVolume CalculationsCargo Optimization

Capacity Limits by Truck Type

Dry Van (53 ft)

Weight: 80,000 lbs GVW (34,000 lbs payload)
Volume: 4,050 cubic feet
Pallets: 26-30 standard pallets
Density: 8.4 lbs/cubic foot

Optimization Tips

  • •Maximize pallet count for light cargo
  • •Focus on weight distribution for dense cargo
  • •Use floor loading for irregular shapes
  • •Consider double-stacking for light items

Dry Van (48 ft)

Weight: 80,000 lbs GVW (34,000 lbs payload)
Volume: 3,672 cubic feet
Pallets: 24 standard pallets
Density: 9.3 lbs/cubic foot

Optimization Tips

  • •Ideal for urban deliveries
  • •Better maneuverability in tight spaces
  • •Efficient for regional distribution
  • •Consider for multi-stop routes

Refrigerated (53 ft)

Weight: 80,000 lbs GVW (34,000 lbs payload)
Volume: 3,800 cubic feet
Pallets: 26 standard pallets
Density: 8.9 lbs/cubic foot

Optimization Tips

  • •Pre-cool trailer before loading
  • •Load frozen items first
  • •Maintain air circulation paths
  • •Monitor temperature zones

Flatbed (53 ft)

Weight: 80,000 lbs GVW (48,000 lbs payload)
Volume: No height restriction
Pallets: 26-30 pallets (if applicable)
Density: Weight-limited

Optimization Tips

  • •Utilize full weight capacity
  • •Consider cargo height restrictions
  • •Plan for weather protection
  • •Optimize tie-down efficiency

Step Deck

Weight: 80,000 lbs GVW (48,000 lbs payload)
Volume: Variable by deck level
Pallets: 24-26 pallets
Density: Weight-limited

Optimization Tips

  • •Use upper deck for lighter items
  • •Load heavy items on lower deck
  • •Consider loading sequence
  • •Maximize height on lower deck

Capacity Calculation Methods

Different approaches for calculating optimal cargo capacity

Weight-Based Calculation

Formula:Payload ÷ Average Item Weight = Quantity
Example:34,000 lbs ÷ 50 lbs per case = 680 cases
When to Use:

Dense, heavy cargo that will reach weight limit first

Considerations:
  • •Include packaging weight
  • •Account for pallet weight
  • •Consider weight distribution
  • •Factor in dunnage materials

Volume-Based Calculation

Formula:Available Volume ÷ Item Volume = Quantity
Example:4,050 cu ft ÷ 2 cu ft per box = 2,025 boxes
When to Use:

Light, bulky cargo that will reach volume limit first

Considerations:
  • •Account for void space
  • •Consider irregular shapes
  • •Factor in stacking limitations
  • •Include aisle space requirements

Pallet-Based Calculation

Formula:Pallet Positions × Items per Pallet = Quantity
Example:26 pallets × 40 cases per pallet = 1,040 cases
When to Use:

Standard palletized cargo

Considerations:
  • •Verify pallet dimensions
  • •Consider stacking height
  • •Account for pallet weight
  • •Plan for mixed pallet sizes

Density-Based Optimization

Formula:If Density > Threshold, Weight-Limited; If Density < Threshold, Volume-Limited
Example:Density = 15 lbs/cu ft > 8.4 threshold = Weight-Limited
When to Use:

Determining optimal loading strategy

Considerations:
  • •Calculate actual cargo density
  • •Compare to truck threshold
  • •Plan loading accordingly
  • •Consider mixed cargo strategies

Optimization Strategies

Proven methods for maximizing freight efficiency

Cube Utilization

Maximize volume efficiency for light cargo

Techniques:
  • •Use every cubic foot of space
  • •Stack to trailer ceiling
  • •Fill void spaces with smaller items
  • •Consider custom packaging
Best For:

Light, bulky items like pillows, packaging materials

Weight Distribution

Optimize weight placement for safety and efficiency

Techniques:
  • •Place heaviest items over axles
  • •Distribute weight evenly left to right
  • •Keep center of gravity low
  • •Balance front-to-back weight
Best For:

Dense, heavy items like machinery, metals

Mixed Loading

Combine different cargo types for optimal utilization

Techniques:
  • •Pair heavy and light items
  • •Use density complementing
  • •Stack compatible products
  • •Fill gaps with smaller items
Best For:

LTL shipments, consolidated loads

Specialized Configurations

Custom loading for unique cargo requirements

Techniques:
  • •Floor loading for irregular shapes
  • •Hanging systems for garments
  • •Rack systems for long items
  • •Temperature zones for mixed loads
Best For:

Specialized cargo, unusual dimensions

Common Capacity Planning Mistakes

❌Not considering cargo density before loading
❌Ignoring weight distribution requirements
❌Underestimating void space in volume calculations
❌Forgetting to include packaging and pallet weights
❌Not accounting for loading/unloading accessibility
❌Overlooking cargo compatibility issues
❌Miscalculating cube utilization potential
❌Ignoring DOT weight regulations

Quick Reference

Standard Measurements

  • • GMA Pallet: 48" × 40" × 5.5"
  • • Dry Van: 53' × 8.5' × 9'
  • • Max GVW: 80,000 lbs
  • • Max Payload: 34,000 lbs (van)

Density Thresholds

  • • Dry Van (53'): 8.4 lbs/cu ft
  • • Dry Van (48'): 9.3 lbs/cu ft
  • • Reefer: 8.9 lbs/cu ft
  • • Flatbed: Weight-limited

Key Formulas

  • • Density = Weight ÷ Volume
  • • Volume = L × W × H
  • • Payload = GVW - Truck Weight
  • • Utilization = Used ÷ Available