How Many Pallets Fit in a Truck: A Comprehensive Guide

Introduction

Dispatchers ask this every day because it drives rates, timelines, and whether a shipment moves in one piece or splits: How Many Pallets Fit in a Truck. The answer depends on three things you control (pallet dimensions, pallet orientation, and loading techniques) and three you cannot (true interior dimensions of the equipment, legal weight limits, and door/obstruction clearances). In this guide I’ll give you the practical counts for a 53-foot trailer, a 48-foot trailer, and a 26-foot box truck, plus the math behind them so you can adjust for your own gear. I’ll show typical ranges, then call out constraints like door opening width, side clearance, and axle weight limits so the plan on paper actually survives the dock.

Bottom line (quick): with standard 48×40 in pallets, a 53′ dry van/reefer typically takes 26 pallets using straight loading, 28 with pinwheeled loading, and up to 30 with tight sideways loading if the door opening and trailer width allow. A 48′ trailer takes 24–26. A 26′ box truck takes 12 (occasionally 13–14 under ideal specs). With Euro pallet (1200×800 mm), theoretical counts are higher where trailer width allows three-across, but operational realities—strapping, dunnage, and the door frame—often bring you back down.

Standard Pallet Sizes

Before we talk trucks, lock down the pallet dimensions. Capacity isn’t just length × width of the trailer; it’s how consistently your pallets conform to a standard and how you orient them.

Euro Pallet Dimensions

The most common European footprint is EUR-1 at 1200 × 800 mm (≈ 47.2 × 31.5 in). Other standardized pallets include EUR-2 (1200 × 1000 mm) and EUR-3/EUR-6, but for freight shipping the EUR-1 dominates general merchandise. Because 800 mm × 3 columns is 2400 mm (≈ 94.5 in), many trailers can run three-across; that single fact changes the math dramatically.

Standard Pallet Dimensions

In North America, the “standard pallet” (often called GMA) is 48 × 40 in (1219 × 1016 mm). Real-world variance matters: boards that flair, pallet overhang, or stretch wrap bulges can add 0.5–1.0 in to each side. Note also stacking height and load height—most dry vans offer 110–110.5 in interior height at centerline (≈ 2.79 m), but the door header can reduce usable height by several inches.

Truck Types and Capacities

Numbers below assume a typical dry van or reefer with flat walls (no wheel wells), and interior width around 100–101 in (≈ 2.54–2.57 m). Reefers often lose a little interior length to the bulkhead.

Useful formula.

Pallets per row = ⌊ usable width / pallet width (as oriented) ⌋

Rows = ⌊ usable length / pallet length (as oriented) ⌋

Total pallets = (pallets per row) × (rows)

53-Foot Trailers

Interior length: ~ 630–636 in (16.0–16.15 m)
Trailer width (usable): ~ 98–100 in at the scuff line (2.49–2.54 m)
Interior height: ~ 108–110 in (2.74–2.79 m) at center; door header can be 104–108 in

48×40 in pallets (North America):

Straight loading: 2 across (2×40 = 80 in) × 13 rows (13×48 = 624 in) = 26 pallets.
Pinwheeled loading: strategic rotation increases use of width/length; 28 pallets is realistic in many vans.
Sideways loading: 2 across (2×48 = 96 in) × 15 rows (15×40 = 600 in) = 30 pallets, but check door opening width; many doors are 93–95 in clear, which makes two sideways pallets (96 in) marginal. If the door is tight or pallets swell, you’ll hang up. Consider this an advanced loading technique for experienced crews.

EUR-1 1200×800 mm pallets (Europe/International):

Math says 3 across (3×800 = 2400 mm) × 13 rows (13×1200 = 15 600 mm) ≈ 39 pallets in a 53′.
Operationally, plan 36–39, depending on cargo alignment, corner protection, and freight staging needs for stops. Many fleets cap at 36 to allow strapping and airflow at the bulkhead.

48-Foot Trailers

Interior length: ~ 565–576 in (14.35–14.63 m)

48×40 in pallets:

Straight loading: 2 across × 12 rows = 24 pallets.
Pinwheeled loading: 26 pallets is common if the interior width is generous and product isn’t bulging.

EUR-1 pallets:

Three-across × 12 rows ≈ 36 pallets theoretical. As with 53′, expect a practical cap slightly lower when you need dunnage or mixed picks.

26-Foot Box Trucks

Interior length: commonly 300–312 in (7.62–7.92 m)
Interior width: 96–100 in (2.44–2.54 m); door width often narrower (88–92+ in)
Interior height: 102–110 in depending on body

48×40 in pallets:

Straight loading: 2 across × 6 rows = 12 pallets (the planning default).
Pinwheeled loading: occasionally 13 if the body gives you those extra inches.
Sideways loading: 2 across × 7 rows (7×40 = 280 in) ≈ 14, but most roll-up doors won’t pass 2×48 = 96 in at the frame. Feasible only with wide doors and tight-lived pallets.

EUR-1 pallets:

Three-across × 6 rows = 18 pallets theoretical; door width again decides whether the first row even gets in.

Loading Techniques

Loading techniques are your biggest lever once equipment is set. Each pattern trades aisle space, restraint options, and door clearance.

Straight Loading

All pallets oriented the same way (for 48×40, the 48 in side aligned with trailer length).

Pros: fastest, simplest, maximizes strap access; counts are predictable (26 in a 53′, 24 in a 48′, 12 in a 26′).

Cons: doesn’t squeeze the last row into tight tolerances; less trailer space optimization than other patterns.

Pinwheeled Loading

Alternate orientation row by row or within a row so the pallet footprint interlocks.

Pros: typically adds +2 pallets versus straight in 48–53′ equipment; helps with space utilization when products don’t overhang the pallet.

Cons: requires a loader who understands the pattern; odd corners can complicate cargo alignment for multi-stop loads.

Sideways Loading

Pallets turned so the 40 in side runs lengthwise (for 48×40), allowing more rows.

Pros: maximum pallets per trailer potential (e.g., 30 in a 53′).

Cons: the deal-breaker is the door: two pallets sideways measure 96 in across; if door clear is <96 in, you can’t physically load the last rows. Also, you’ll have tighter side clearance to the scuff plate and higher risk of pallet overhang catching at the jamb.

Factors Affecting Pallet Capacity

Pallet Overhangs

Even “standardized pallets” aren’t perfectly standard in the wild. Deckboards flare, shrink wrap bulges, and product corners extend past the pallet. A pallet overhang of even ½ in each side turns 48×40 into 49×41—tiny on paper, painful at the door. Overhang reduces trailer capacity, breaks pinwheel patterns, and creates rub points that fail retail compliance.

Weight Distribution

Counts mean nothing if you blow axle weight limits. Plan with weight per pallet and a rough pallet density (mass per pallet footprint and height). Spread heavier SKUs over the first third and over drives, never pack all dense pallets at the nose. Most U.S. 5-axle combinations cap at 80,000 lb GVW (with per-axle limits), but local legal weight limits and permit rules vary. For reefers, add fuel weight. For box trucks, verify payload capacity on the door placard; a 26′ that “fits” 14 pallets may still overload if those pallets are tile or liquids.

Loading Techniques

Which technique you use affects weight spread and securement:

Straight loading makes even distribution easier and improves strap/airbag placement.
Pinwheeled loading can cluster corners; watch for point loads on the floor.
Sideways loading tends to push more weight aft; check tandem settings and scale after the first stop.

Maximizing Trailer Space

Stackable vs. Non-Stackable Pallets

Two identical counts can carry wildly different cubic volume. If you have stackable pallets, verify stacking height rules with the consignee and account for interior height versus load height (don’t ignore the door header and reefer chute). Non-stackable pallets demand floor spread (floor loading is sometimes allowed for soft goods but raises damage risk). Clear “mixed pallet sizes” policies for multi-SKU lanes so you don’t strand short pallets that could stack.

Advanced Loading Techniques

Use these when you need that last row without compromising safety:

Micro-pinwheel within a row. Turn just two pallets at the tail or nose to gain 1–2 in of effective length.
Staggered flush/offset. Keep the driver-side column perfectly straight (for strap line), offset the curb-side by 1–2 in to absorb pallet irregularities.
High/low stacking (same SKU). Stack where packaging is rated to carry it; never mix fragile on bottom.
Inverted “T” bracing with dunnage to stabilize partial last rows.
Door-first test. Before committing to a sideways or three-across pattern, dry-fit two pallets through the door to confirm jamb clearance.
Border clearance planning. If your load crosses a border, leave enough space for inspection access and to re-secure after customs. This may drop your theoretical count by 1–3 pallets but saves time and rehandling.

Conclusion

If you remember nothing else, remember this: counts are a function of pallet footprint, orientation, and the true, measured interior of the equipment—including the door. In everyday U.S. work, a 53′ trailer holds 26 straight, 28 pinwheel, and at best 30 sideways (with excellent equipment and loaders). A 48′ usually runs 24 straight and 26 pinwheel. A 26′ box truck runs 12, with occasional 13–14 only when the body and door allow. With Euro pallet (1200×800), the math suggests three-across in many bodies, boosting counts—but plan conservatively when strapping, air chutes, or mixed picks are in play.

For planners and dispatchers, here’s a simple workflow for load planning that keeps both trailer space optimization and compliance in view:

Confirm the equipment’s usable interior length/width/height (tape it once; don’t trust a brochure).
Verify pallet compatibility and exact outside measurements of the freight—don’t assume the SKU stays inside the pallet deck.
Choose the loading technique (straight loading first; escalate to pinwheeled loading or sideways loading only with door tests).
Simulate weight distribution with a quick spreadsheet: enter weight per pallet, target payload capacity, and check axle weight limits after each row.
Stage freight in the right order on the dock (freight staging), then load, scale, and adjust tandems.
Document the plan with photos of the first and last rows for claims defense.

Finally, do what seasoned drivers do: scale early, scale often, and listen to the freight. When you brake and it shifts, it’s telling you about your space utilization, not just your miles per hour.

Appendix: Handy Reference Counts (Typical)

53-foot trailer (48×40 in): 26 straight • 28 pinwheel • up to 30 sideways (tight door tolerance).
48-foot trailer (48×40 in): 24 straight • 26 pinwheel.
26-foot box truck (48×40 in): 12 straight • 13–14 only where door/body allow.
53-foot trailer (EUR-1): 36–39 depending on strapping/airflow.
48-foot trailer (EUR-1): up to 36 theoretical; often plan slightly lower for securement.
26-foot box truck (EUR-1): up to 18 theoretical; door may limit.

Compliance & Safety Note

Figures above are typical and assume dry van/reefer interiors in good condition. Real equipment varies by manufacturer and year. Legal weight limits and per-axle rules differ by jurisdiction, and trailer width, interior height, door opening size, and hardware (E-track, scuff plate) may reduce capacity. Always measure your specific unit, confirm requirements with the shipper/receiver, and scale before departure.