Ever wondered why one truckload sometimes means 26 pallets and other times 30? Misjudge it, and you’re not just short two pallets—you might be paying for a whole extra truck. A 53ft trailer usually fits 26–30 pallets, a 48ft fits 24–28, and a 26ft box truck takes 12–14, or up to 28 stacked.
The difference isn’t luck—it’s how pallets are sized, placed, and stacked. In this guide, written from a pallet manufacturer’s view, we’ll show you the real math behind truck capacity, the loading methods that squeeze in extra rows, and the hidden limits like overhang or weight laws. By the end, you’ll plan loads with confidence—and stop paying to ship empty air.
What Loading Methods Determine Pallet Capacity?
The way pallets are placed inside the truck explains why the number changes. Each method uses space differently and may need different equipment.
Straight Loading
Pallets face lengthwise, with the 48-inch side along the truck. Two pallets sit side by side, row after row. Any pallet jack can handle this, which makes it the most common style. But unused width means fewer rows fit compared to other layouts.
Sideways Loading
The 40-inch side faces the truck length. This lets you squeeze in more rows within the same space. Block pallets work well, but stringer pallets need a forklift or jacks with side forks. It improves capacity but adds handling limits.
Pinwheel Loading
Rows alternate between straight and sideways, forming a “pinwheel.” It closes gaps and gains a couple of extra pallets. The method saves space but slows loading speed, and it requires more careful placement to avoid misalignment.
Stackable Loading
When goods are stable and the roof height allows, pallets can be stacked in two layers. A 53ft trailer that holds 26 on the floor can carry 52 stacked. It’s efficient, but only safe if products can take the weight and weight limits are respected.
How Many Pallets Fit on a 53-Foot Truck?
A 53ft truck is the standard choice for full truckload freight in North America, usually carries 26 to 30 standard pallets, depending on how they are loaded.
The inside of a 53ft trailer is about 636 inches long, 102 inches wide, and 110 inches high. A standard 48×40 pallet, also called GMA pallet, takes up 48 inches by 40 inches on the floor.
Straight Loading: Wach pallet uses its 48-inch side along the trailer’s 636-inch length. Two pallets fit across the 102-inch width, and 13 rows fit down the length, so the total is 26.
Pinwheeled Loading: When pallets are set in a mixed pattern, the long side and short side alternate, filling extra gaps. This way, about 28 can be placed.
Sideways Loading: If you turn every pallet so the 40-inch side runs along the length, 15 rows fit instead of 13, which gives you 30.
When the pallets are heavy-duty and the product weight is lighter, you can stack a second layer. In that case, the truck can move up to 52 pallets, but only if the total height clears the roof and axle weight stays within legal limits.
How Many Pallets Fit on a 48-Foot Trailer?
A 48ft trailer usually carries 24 to 28 standard 48×40 pallets. That is slightly fewer than a 53ft truck, which holds 26 to 30, because the trailer is 60 inches shorter.
Straight Loading: With the 48-inch side placed along the 576-inch length, two pallets fit across the 102-inch width. Twelve rows fit down the trailer, so the total is 24.
Pinwheeled Loading: Alternating the long and short sides helps close gaps. This pattern usually adds two more pallets, giving you 26 in total.
Sideways Loading: When the 40-inch side faces the trailer length, 14 rows can fit instead of 12. That makes the count 28, which is the maximum in a 48ft trailer without stacking.
How Many Pallets Fit on a 26ft Box Truck?
A 26ft box truck usually carries 12 to 14 pallets in one layer, or 24 to 28 pallets if stacked. It is smaller than long-haul trailers and is often used for local deliveries, so planning space well makes a big difference.
Single Layer
The trailer length is 312 inches. With pallets set at 48 inches long, six rows fit. Two pallets across the 96-inch width give you 12 total. If you rotate them so the 40-inch side faces forward, seven rows fit, reaching 14 pallets.
Double Layer
If pallets are heavy-duty and goods are stable, you can place another layer. This doubles the load to 24–28 pallets, but only if total height stays under the 96-inch roof and the weight is within limits.
Empty Pallets Only
When shipping pallets themselves, stacking changes the math. With each pallet about 6 inches thick, you can load 192–224 empty pallets in a 26ft truck.
Safety and Efficiency
Stacking saves space, but only when products are stable. Always leave clearance under the roof and balance the weight. For short-haul trucks like the 26ft, also keep in mind that easy loading and unloading is often more valuable than squeezing in one extra pallet.
How Many Pallets Fit in 16ft, 24ft, 40ft, and 45ft Trucks?
Not every shipment goes into a 53ft or 26ft truck. Medium box trucks and international containers are also widely used in freight. The numbers below show single-layer capacity only, based on standard 48×40 pallets without stacking.
| Truck / Container | Pallet Count (Single Layer) | Notes |
|---|---|---|
| 16ft Box Truck | 6–8 pallets | Local delivery, limited space |
| 24ft Box Truck | 12–14 pallets | Often used in regional transport |
| 40ft Container | 20–24 pallets | Standard in ocean shipping |
| 45ft Cube Container | 24–26 pallets | More space than 40ft, used for international routes |
Does Pallet Size Change Truck Capacity?
Yes, pallet size directly changes how many pallets fit in a truck. A standard 48×40 pallet gives the most flexibility, but other common sizes create different totals.
| Pallet Size | 53ft Trailer | 48ft Trailer | 26ft Truck | Notes |
|---|---|---|---|---|
| 48×40 (GMA) | 26–30 (52 stacked) | 24–28 | 12–14 (24–28 stacked) | Most efficient, supports all loading patterns |
| 48×48 | 26 | 24 | 12 | Square shape, no gain from pinwheel |
| 42×42 | 30 | 28 | 14 | Square but smaller footprint, higher count |
| 48×45 | 26–28 | 24–26 | 12–13 | Wider footprint, common in automotive |
How to Calculate Pallet Capacity for Any Truck Size?
If you ever want to figure it out yourself instead of checking a chart, the math is simple. With just the truck’s inside dimensions and the pallet size, you can get a quick answer.
Formula (single layer):
(Truck length ÷ Pallet length) × (Truck width ÷ Pallet width)
For stacking:
Single layer result × (Truck height ÷ Pallet height)
Example for 53ft truck with 48×40 pallets:
- Length: 636 ÷ 48 = 13 rows
- Width: 102 ÷ 40 = 2 pallets across
- Single layer = 13 × 2 = 26 pallets
- With stacking (110 ÷ 48 ≈ 2 layers): 52 pallets
This way, you can check any truck size in seconds, as long as you know the inside length, width, and height.
Other Factors That Limit Pallet Loading
You may already know pallet size and stacking change the numbers, but they’re not the whole story. In real shipping, weight, overhang, and legal limits often decide whether all those pallets can actually fit.
Weight Restrictions: A truck may “weigh out” before it “cubes out.” Heavy goods can hit the legal weight limit with fewer pallets.
Pallet Overhang: If boxes extend even 2–3 inches beyond a pallet, an entire row may not fit, forcing you to remove pallets.
Safety and Compliance: Axle load balance, roof clearance, and door access all matter. Overloading or poor distribution risks fines, accidents, and damaged goods.
Conclusion
A standard 48×40 pallet usually means 26–30 in a 53ft truck, 24–28 in a 48ft, and 12–14 in a 26ft box truck. These numbers define what a full load really is and give you a clear baseline for planning. Knowing how many pallets fit on a truck is not just about numbers—it’s about saving freight costs, protecting goods, and planning with certainty.
As a plastic pallet manufacturer, we help you match plastic pallet design with truck space, so you move more with less. Custom sizes, fair pricing, and durable products mean no wasted spend and no shipping guesswork.
👉 Contact us today for a tailored quote and pallet solution that fits your load and your budget.
