Weight and payload of the van
Every kilogram that a fit-out takes up is deducted from the vehicle's payload, that is, from how much in tools, material and people you can carry. At first glance it looks like a trifle, but in practice it is one of the most important things to address even before the design.
Videa
How it is calculated
A van has its unladen weight and its maximum permitted weight. The difference is what you may load, including the driver, passengers, fuel, fit-out, tools and materials. The fit-out is the first item that eats into this difference, and it stays there whether you are carrying a full load or none. That is why it makes sense to ask about the weight not only of the whole fit-out but also of its individual parts, and always to compare it with what you actually carry.
Why a lightweight structure matters
A lighter fit-out means more payload, lower fuel consumption and less strain on the chassis and brakes. For vans that travel with tools, materials and often other people too, this is a difference that shows on every trip. That is why we build from aluminium profiles, use steel only where we really need strength, and offer shelf panels in a lighter plastic version.
Where heavy items belong
A well-designed layout puts heavy items low and as close to the vehicle's axis as possible, light ones high and at the edges. Heavy cargo placed high or far behind the rear axle worsens stability in corners and lengthens the braking distance. The rear axle also needs to be watched separately: a vehicle may be within the overall limit and still overload the rear axle when everything is at the back. When designing, we therefore position heavy parts, such as drawers with tools, cases or a generator, with the centre of gravity in mind.
Load distribution from side to side
If a fit-out has shelves on one side only, it loads the vehicle unevenly. Regardless of whether it is on the left or right side, it is good to make sure that heavy parts are balanced by the opposite side or the centre. For some vehicles we therefore recommend splitting the load between both sides or keeping heavy items in the middle.
What to do when the vehicle is at its limit
If you carry a lot of heavy material, a fit-out with a full load may not fit within the limit. The solution is a lighter version of the structure, removal of unnecessary parts, moving heavy items to the rear removable platform, which is taken out when not needed, or choosing a vehicle with a higher load capacity. We will advise what makes the most sense in your particular situation.
Driving licence and weight groups
The weight of the vehicle and fit-out affects which driving licence group you may drive. For vehicles close to the limit it is worth checking whether you remain within the limits of your category with the fit-out and load.
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