Truck load calculator inputs
Example data table
| Scenario | Truck size (m) | Unit size (m) | Unit weight (kg) | Requested units | GVW / Empty (kg) | Likely bottleneck |
|---|---|---|---|---|---|---|
| Standard curtain trailer | 13.6 × 2.45 × 2.70 | 1.2 × 1.0 × 1.4 | 850 | 26 | 40,000 / 14,500 | Weight |
| Light cartons | 7.2 × 2.40 × 2.40 | 0.8 × 0.6 × 0.5 | 120 | 180 | 18,000 / 6,000 | Space |
| Dense industrial crates | 9.0 × 2.45 × 2.60 | 1.1 × 1.1 × 1.3 | 1,200 | 20 | 32,000 / 11,200 | Axle / weight |
Formula used
Truck internal volume: truck length × truck width × truck height
Usable volume: truck internal volume × (1 − unusable space %)
Unit volume: unit length × unit width × unit height
Floor positions: floor(truck length / unit length) × floor(truck width / unit width)
Allowed stack levels: min(max stack levels, floor(truck height / unit height))
Space capacity: floor positions × allowed stack levels
Payload capacity: GVW limit − empty vehicle weight
Safe payload capacity: payload capacity × (1 − safety buffer %)
Weight capacity units: floor(safe payload capacity / unit weight)
Volume capacity units: floor(usable volume / unit volume)
Recommended loaded units: minimum of requested, space capacity, weight capacity, and volume capacity
Loaded axle weight: empty axle weight + actual load weight × axle share
How to use this calculator
Enter the truck interior dimensions in meters. Use real usable measurements, not outside body measurements.
Fill in the legal gross vehicle limit and the empty vehicle weight. The calculator derives payload capacity automatically.
Enter one cargo unit size and its gross weight. This unit can represent a pallet, crate, carton stack, or drum position.
Set the requested unit count, stacking limit, unusable space percentage, and a safety buffer for practical loading conditions.
Provide empty axle weights and legal axle limits. Then assign how much of the cargo load should sit on each axle group.
Press Calculate Truck Load. Review the recommended quantity, limiting factor, utilization values, axle checks, and export buttons.
FAQs
1. What does this calculator optimize?
It compares physical fit, cube use, payload capacity, gross weight, and axle exposure. That makes it useful for dispatch planning, warehouse staging, and shipment feasibility checks before loading begins.
2. Why can recommended units be lower than requested units?
The requested quantity may exceed available space, safe payload, usable cube, or axle margins. The tool selects the lowest feasible capacity so the result stays operationally realistic.
3. What is unusable space percentage?
It accounts for door clearance, bracing, dunnage, irregular packing gaps, and access space. Reducing usable cube helps the output reflect real trailer conditions instead of perfect geometry.
4. Why include a safety buffer?
A buffer protects against weighing variation, packaging changes, moisture gain, and route-specific restrictions. Many planners prefer a small reserve rather than loading to the exact mathematical limit.
5. How are axle loads estimated?
The calculator spreads actual cargo weight across front, drive, and trailer groups using your percentage shares. It then adds those values to empty axle loads for a simplified planning estimate.
6. Can I use this for non-pallet cargo?
Yes. Replace pallets with crates, bins, rolls, drums, or carton stacks. Just enter one repeatable cargo unit size, weight, and the number of units you want loaded.
7. Does this replace a legal weight certificate?
No. It is a planning tool, not a legal certification system. Actual compliance should still be confirmed using site scales, route rules, and vehicle-specific regulatory checks.
8. What if the empty axle weights do not match tare weight?
The calculator flags that mismatch because it can distort axle estimates. Update axle baselines from a recent weighbridge record for more dependable distribution and compliance planning.