Truck Loading
Efficient truck loading is essential for optimizing transportation costs, ensuring load stability, and maximizing the use of available space. This section covers truck types, loading configurations, and best practices for pallet transportation.
Truck Types and Specifications
Different shipping needs require specialized trailer types. Each trailer type offers unique advantages and has specific capacity limitations.
Dry Van Trailers
The most common trailer type for pallet shipping, offering enclosed protection from the elements.
| Specification | 53' Dry Van | 48' Dry Van | Notes |
|---|---|---|---|
| Interior Length | 636" (53') | 576" (48') | Standard shipping length in the U.S. |
| Interior Width | 98-100" | 98-100" | Most commonly 100" (8'4") |
| Interior Height | 108-110" | 108-110" | Most commonly 108" (9') |
| Door Opening Height | ~110" | ~110" | Slightly less for overhead doors |
| Door Opening Width | ~96" | ~96" | Double rear doors |
| Maximum Cargo Weight | 42,000-45,000 lbs | 42,000-45,000 lbs | Varies by equipment |
| Standard GMA Pallet Capacity (Straight) | 26 | 24 | 48"×40" pallets |
| Standard GMA Pallet Capacity (Turned) | 30 | 28 | 48"×40" pallets |
| Standard GMA Pallet Capacity (Pinwheeled) | 28 | 26 | 48"×40" pallets |
Dry vans offer the most versatile shipping option for palletized goods, providing protection from weather and security against theft.
Refrigerated (Reefer) Trailers
Designed for temperature-controlled shipping needs, with slightly smaller interior dimensions due to insulation.
| Specification | 53' Reefer | 48' Reefer | Notes |
|---|---|---|---|
| Interior Length | 630-632" | 570-572" | Slightly less than dry van due to cooling unit |
| Interior Width | 96-98" | 96-98" | Narrower due to insulation |
| Interior Height | 103-105" | 103-105" | Lower due to insulation and cooling equipment |
| Maximum Cargo Weight | 42,000-44,000 lbs | 42,000-44,000 lbs | Slightly less due to refrigeration unit weight |
| Standard GMA Pallet Capacity (Straight) | 24 | 22 | 48"×40" pallets |
| Standard GMA Pallet Capacity (Turned) | 28 | 26 | 48"×40" pallets |
| Temperature Range | -20°F to 70°F | -20°F to 70°F | Adjustable for various commodities |
Air circulation is critical in refrigerated trailers. Proper loading techniques must allow for air flow around the entire load.
Flatbed Trailers
Open trailers for oversized or irregularly shaped cargo that doesn't require protection from the elements.
| Specification | 48' Flatbed | 53' Flatbed | Notes |
|---|---|---|---|
| Deck Length | 48' | 53' | Measurements exclude the tractor |
| Deck Width | 102" | 102" | Standard width |
| Deck Height | ~60" | ~60" | From ground to deck surface |
| Maximum Cargo Weight | 48,000 lbs | 48,000 lbs | Slightly more than enclosed trailers |
| Standard GMA Pallet Capacity | 24 | 26 | Requires proper securing and tarping if needed |
| Side Loading | Yes | Yes | Can be loaded from sides, rear, or top |
| Weather Protection | None | None | Tarps required for weather-sensitive cargo |
Step-Deck (Drop Deck) Trailers
Similar to flatbeds but with a lower deck height for taller loads.
| Specification | Standard Step Deck | Notes |
|---|---|---|
| Upper Deck Length | 10-11' | Front section |
| Lower Deck Length | 37-43' | Main cargo area |
| Width | 102" | Standard width |
| Upper Deck Height | ~60" | Same as standard flatbed |
| Lower Deck Height | 36-42" | Allows for taller cargo |
| Maximum Cargo Weight | 45,000 lbs | Variable by equipment |
| Standard GMA Pallet Capacity | 24 | Requires proper securing and tarping if needed |
| Max Legal Cargo Height (Lower Deck) | 10' | Without permits |
Pallet Quantities by Size and Trailer Type
The number of pallets that fit in a trailer depends on both the pallet dimensions and the loading configuration.
53' Dry Van Capacity by Pallet Size
| Pallet Size | Straight Load | Turned Load | Pinwheel Load | Notes |
|---|---|---|---|---|
| 48"×40" (GMA) | 26 | 30 | 28 | Most common pallet size in the U.S. |
| 42"×42" | 30 | 30 | N/A | Common for paint and beverage products |
| 36"×36" | 34 | 34 | N/A | Often used for beverages |
| 48"×48" | 26 | 26 | N/A | Used for barrels and drums |
| 48"×45" | 28 | 24 | N/A | Common in automotive industry |
| 40"×48" (EURO) | 30 | 26 | 28 | European standard pallet |
For 48"×40" pallets, the traditional calculation suggests 26 pallets when loaded straight (13 rows × 2 pallets). However, some professional loaders can fit up to 30 pallets using advanced techniques.
Loading Techniques
Straight Loading
Straight loading is the most common and straightforward loading method.
How it works:
- Pallets are loaded with the 48" side facing the sides of the trailer
- The 40" side faces the front and rear of the trailer
- Pallets are arranged in two columns down the length of the trailer
Advantages:
- Fastest loading method
- Easiest to plan and execute
- Can load multiple pallets at once with extended forklifts
- Simplifies load planning
Disadvantages:
- Does not maximize trailer capacity
- May leave more space for load shifting
Calculation for 48"×40" pallets in a 53' dry van:
- Trailer length (636") ÷ Pallet width (40") = 15.9 pallets
- Can fit 15 pallets lengthwise
- Trailer width (100") allows 2 pallets side-by-side
- Total capacity: 15 × 2 = 30 pallets theoretically (26 standard practice)
Turned Loading
Turned loading rotates the pallets 90 degrees from the straight loading orientation.
How it works:
- Pallets are loaded with the 40" side facing the sides of the trailer
- The 48" side faces the front and rear of the trailer
- Pallets are arranged in two columns down the length of the trailer
Advantages:
- Increases capacity for standard GMA pallets
- Can fit 30 pallets instead of 26 for 48"×40" pallets
- Reduces space between pallets, minimizing load shifting
Disadvantages:
- Requires four-way entry pallets
- Can be more difficult to load
- May not work with all pallet types
- Tighter fit makes loading/unloading more time-consuming
Calculation for 48"×40" pallets in a 53' dry van:
- Trailer length (636") ÷ Pallet width (48") = 13.25 pallets
- Can fit 13 pallets lengthwise
- Trailer width (100") allows 2 pallets side-by-side
- Total capacity: 13 × 2 = 26 pallets
Pinwheel Loading
Pinwheel loading alternates the direction of adjacent pallets to maximize space utilization.
How it works:
- Alternating pallets are turned 90 degrees to each other
- One pallet is placed with its 48" side parallel to the trailer side
- The adjacent pallet is placed with its 40" side parallel to the trailer side
- This pattern continues throughout the trailer
Advantages:
- Optimizes space utilization
- Improves load stability through interlocking pattern
- Reduces shifting during transit
- Works well for mixed pallet sizes
Disadvantages:
- More complex and time-consuming to load
- Requires skilled forklift operators
- May be difficult to unload in sequence
Calculation for 48"×40" GMA pallets in a 53' dry van:
- Calculate available width: 100" - 48" = 52" remaining
- 52" - 40" = 12" remaining (enough for securement)
- Each row can fit one 48" pallet and one 40" pallet side by side
- Can fit 14 rows of these pairs
- Total capacity: 28 pallets
Weight Distribution Loading
For heavy pallets, proper weight distribution is more important than maximizing the number of pallets.
How it works:
- Heavier pallets are placed toward the center of the trailer
- Pallets are arranged to distribute weight evenly across axles
- May alternate between single and double rows
Advantages:
- Ensures legal axle weight limits are maintained
- Improves vehicle handling and safety
- Reduces risk of fines and regulatory issues
Disadvantages:
- Reduces total pallet capacity
- More complex loading process
- May require specific loading sequence
The total weight of a loaded truck and trailer cannot exceed 80,000 pounds in most U.S. states. After accounting for the weight of the tractor and trailer, the maximum cargo weight is typically 42,000-45,000 pounds. Always distribute weight evenly throughout the trailer.
Loading Best Practices
Safety Considerations
- Ensure the trailer is properly secured and stabilized before loading
- Use wheel chocks to prevent trailer movement during loading
- Inspect the trailer floor for damage or weakness before loading
- Maintain proper clearance for forklift operation
- Ensure proper lighting for visibility
Load Stabilization
- Use dunnage between pallet layers when stacking
- Apply stretch wrap to secure unstable loads
- Consider load bars for partial loads to prevent shifting
- Use airbags between pallets for loads that don't fill the width
- Place heavier items on the bottom when stacking
Maximizing Space
- Consider double-stacking when product allows
- Use slip sheets for lightweight products to reduce pallet weight
- Plan mixed loads carefully to optimize space
- Align pallets flush with each other to eliminate gaps
Documentation
- Create a load diagram for complex loading patterns
- Document weight distribution for heavy loads
- Record pallet positions for easy identification at delivery
- Photograph loaded trailer before closing doors
Industry-Specific Loading Considerations
Food and Beverage
- Maintain proper temperature zones in refrigerated trailers
- Keep raw and finished products separated
- Ensure proper airflow around refrigerated products
- Consider product dating for FIFO (First In, First Out) unloading
Retail
- Arrange pallets according to store delivery sequence
- Group products by department when possible
- Keep high-value items secure and visible
- Consider cross-docking requirements in load planning
Manufacturing
- Prioritize just-in-time delivery components
- Protect sensitive components from vibration
- Consider production line sequence for unloading
- Separate raw materials from finished goods
Construction
- Load heaviest materials first
- Arrange materials according to construction phase
- Keep frequently needed items accessible
- Protect moisture-sensitive materials
Regulatory Considerations
Weight Limits
- Maximum gross vehicle weight: 80,000 lbs in most states
- Typical maximum payload: 42,000-45,000 lbs
- Tandem axle weight limit: 34,000 lbs
- Single axle weight limit: 20,000 lbs
Securement Requirements
- All cargo must be secured to prevent shifting
- Minimum working load limit requirements vary by cargo weight
- Proper tie-down methods vary by cargo type
- Regular inspections required during transit
Oversize Loads
- Permits required for loads exceeding legal dimensions
- Escort vehicles may be required
- Time-of-day restrictions may apply
- Route restrictions for oversize loads
EMPTY PALLET TRANSPORTATION (PALLET RECYCLING & MANUFACTURERS)
This section is specifically about transporting EMPTY PALLETS THEMSELVES for pallet recycling companies, pallet manufacturers, or pallet recovery operations - NOT about shipping goods on pallets.
Empty Pallet Capacity by Trailer Type
| Trailer Type | Empty Pallet Capacity (Standard GMA Pallets) | Notes |
|---|---|---|
| 53' Dry Van | 500-616 | Depends on stacking method and pallet condition |
| 48' Dry Van | 450-550 | Slightly less capacity than 53' |
| Flatbed | 450-550 | Requires proper securement and possibly tarping |
| Step Deck | 400-500 | Lower capacity due to deck configuration |
Stacking Methods for Empty Pallets
Nested Stacking
- Empty pallets stacked directly on top of each other
- Typically allows 15-18 empty pallets per stack
- Simpler to load but may not maximize space
- Capacity: ~500-540 empty standard pallets in a 53' dry van
Alternating/Interlocked Stacking
- Empty pallets arranged in alternating directions between layers
- Creates more stable, interlocking stacks
- More time-consuming to load but maximizes space utilization
- Capacity: ~550-616 empty standard pallets in a 53' dry van
Column Stacking
- Empty pallets organized in vertical columns throughout the trailer
- Easier to count and track inventory
- Facilitates even weight distribution
- Works well for uniform empty pallet types
Total Empty Pallet Capacity Calculation
The total number of empty pallets per truckload is directly determined by:
- Number of stacks (rows × columns)
- Height of each stack (number of pallets per stack)
Key Formula: Total empty pallets = Number of stacks × Stack height
Example calculations for empty pallets in a 53' dry van:
- 26 stacks × 20 pallets high = 520 empty pallets
- 26 stacks × 21 pallets high = 546 empty pallets
- 26 stacks × 22 pallets high = 572 empty pallets
- 28 stacks × 22 pallets high = 616 empty pallets
For pallet recycling operations, the stack height is the most critical factor in maximizing loads. The difference between stacking 20 vs. 22 empty pallets per stack can increase total capacity by 50-60 empty pallets per truckload.
Stack Height Considerations for Empty Pallets
- Maximum safe stack height: 20-25 empty pallets depending on pallet condition and type
- Industry standard for empty GMA pallets: 15-22 pallets per stack
- Factors affecting maximum stack height:
- Pallet condition (damaged pallets should be stacked lower)
- Pallet material (plastic pallets may allow higher stacks than wood)
- Trailer height restrictions (interior height minus clearance)
- Stability requirements
- Weight distribution
Loading Considerations for Empty Pallets
- Weight: A full load of empty wooden pallets typically weighs 15,000-25,000 lbs (well below trailer weight limits)
- Condition: Sort pallets by condition before loading; damaged pallets may require different stacking methods
- Size mixing: When transporting mixed pallet sizes, organize by size for optimal space utilization
- Security: Secure stacks with straps, bands, or shrink wrap to prevent shifting
- Loading sequence: Load from front to back in even rows, maintaining balanced weight distribution
- Height restrictions: Ensure stacks don't exceed trailer height limits (typically 108"-110" interior height)
Even though empty pallets weigh less than loaded pallets, proper load securement is still essential to prevent shifting during transit.
Best Practices for Empty Pallet Transport
- Inspect all empty pallets for protruding nails, splinters, or damage that could cause injury during handling
- Sort empty pallets by size, type, and condition before loading
- Use consistent stack heights for easier loading and improved stability
- Consider side-loading when equipment permits for better organization
- Document quantities by type for accurate inventory management
- Distribute weight evenly throughout the trailer
- Secure each stack or section with appropriate strapping
- Consider floor protection for trailers when transporting lower-quality pallets that may shed debris