EN | KZ | RU
Van bodies
Van bodiesIsothermal box bodiesRefrigerated vansDry freight box bodiesIce cream vansBakery vansFlatbed platformsDrop-side with tiltCurtainsiderVan configuratorChassis comparison
Vehicles
In stockMade to orderCompleted projects
Chassis21
JAC8
JAC M4JAC M3JAC N35JAC SunrayJAC N56JAC N200JAC N90JAC N120
GAZelle2
GAZelle BusinessGAZelle Next
KIA2
Kia Bongo K2500Kia Bongo K4000
FAW2
FAW T80FAW Tiger
Shineray5
Shineray X30LShineray T30Shineray T32Shineray T50Shineray T52
Foton2
Foton Aumark S35Foton Aumark S80
All chassis — 21 models →
Equipment
Refrigeration unitsElingeCarrierKaidaSliding tarpaulinsFAW T80KIA BongoHyundai Porter
Components
HardwareDoor seals for van bodiesLocks, latches and hinges for van bodiesCargo securing in a van bodySide underrun protectionMudguards and mud flaps for van bodiesLadders and steps for van bodiesLighting and marker lamps for van bodiesMounting the body to the chassisBody componentsCompressors
Services
ServicesRefrigeration equipment installationVehicle conversionsVan body repairVan insulationEutectic plates manufacturingCold roomsMobile workshop (PARM)
Trucks in stockBlogFAQGet a quote

Home / Van configurator

Online body calculation

Van configurator — online pallet and volume calculator

Build a body for your task — independent of chassis brand: set the dimensions and sandwich-panel thickness, and the configurator calculates inner dimensions, volume and pallet capacity and draws a layout diagram. For a specific chassis, calculate on the model pages: GAZelle Next · JAC N56.

Body parameters

Choose a preset or build your own — volume and pallet capacity recalculate automatically.

—inner dimensions, mm
—inner volume
—pallets 1200×800
Pallet layout diagram — top view, automatic arrangement.

Send configuration to WhatsApp →

Estimate only: inner dimensions = outer minus two panel thicknesses; capacity is per 1200×800 mm europallet, not counting wheel arches. The exact spec and price are calculated by COND's engineering department on request.

You have the volume — what next:Vehicles in stockRefrigerated bodyAn insulated vanDry-freight bodyA body for your chassis

How many pallets fit in a van — typical bodies

1200×800 mm europallets in one tier, mixed layout (lengthwise and crosswise rows), 50 mm sandwich panel. An exact calculation for your dimensions is in the calculator above.

Body (length × width)InsideEuropalletsTypical chassis
3,200 × 2,000 mm3,100 × 1,900 mm4GAZelle Next, KIA Bongo, FAW T80
4,200 × 2,200 mm4,100 × 2,100 mm8GAZelle Next long, JAC N56
5,200 × 2,300 mm5,100 × 2,200 mm10JAC N56/N90, HINO 300
6,200 × 2,500 mm6,100 × 2,400 mm15JAC N90/N120, Isuzu
7,500 × 2,550 mm7,400 × 2,450 mm18JAC N120, HINO 500, KamAZ
8,200 × 2,600 mm8,100 × 2,500 mm20HINO 500 GD, KamAZ, Dongfeng

For frozen isothermal bodies (80–100 mm panel) the inner dimensions are smaller — check the layout in the calculator: at tight width an 80 mm panel is more efficient.

How many pallets fit in GAZelle, JAC, HINO — by chassis brand

Guidelines for the most common chassis: 1200×800 europallets in one tier. Check your size in the calculator — capacity depends on the wheelbase and body width.

ChassisBodyEuropallets
GAZelle Next / GAZelle Business3.2 m4
GAZelle Next long (A21R33)4.2 m8
KIA Bongo K2500/K4000, Hyundai Porter3.2–4.2 m4–8
JAC N564.2–5.2 m8–10
JAC N905.2–6.2 m10–15
JAC N1206.2–7.5 m15–18
HINO 3004.2–5.2 m8–10
HINO 500, KamAZ, Dongfeng7.5–8.2 m18–20

Need a van for a specific number of pallets? Quick guide: 4 pallets — body from 3.2 m; 6 — from 3.6 m; 8 — from 4.2 m; 10 — from 5.2 m; 15 — from 6.2 m; 18 — from 7.5 m; 20 — from 8.2 m (width 2.2–2.6 m). Set the size in the calculator above to see the layout and gaps.

Why inner dimensions decide everything. A van's capacity is set not by outer dimensions but by inner ones — minus the thickness of the floor, wall and roof sandwich panels. A few centimetres of width is a whole pallet row: a body designed 'by eye' carries air, while one designed around the pallet carries money. That's why before ordering a van it's important to calculate the layout: how many europallets fit in one tier, what gap is left to the walls and whether the height is enough for stacking.

Allow for cargo overhang. Boxes and sacks almost always overhang the pallet — for a tight layout allow 5–8 cm on each side, otherwise the outer row won't fit.

Consider how you will load. A forklift in a non-reinforced van without a metal subframe can break the body — a forklift needs a reinforced floor and subframe. Pallet-jack wheels under a heavy pallet roll over the floor covering and catch the lower doorway trim — for intensive pallet-jack use we fit a wear-resistant floor and galvanised doorway protection. Tell the manager what equipment you load with, and we'll build in the reinforcement.

Plan for side loading. If pallets are loaded from the side by forklift or unloaded at several points, these help side doors or a fully sliding side — curtain-side and curtainsider: the forklift takes any pallet directly, without moving the others.

COND builds vans calculated for your logistics needs: for the pallet type, temperature mode and routes. The engineering department chooses the length, width and panel thickness so the body holds the maximum number of pallets without losing insulation. Profitable logistics starts with the body: one extra pallet row per trip pays back the investment in a well-designed van within the first months — pallet delivery becomes cheaper per space.

Contact us — we'll calculate a van for your task with maximum capacity, build and install it on any chassis in Almaty.

Which van to build

Dry freight Insulated Refrigerated body Bakery van Curtainsider

Calculation for a specific chassis

GAZelle Next + configurator JAC N56 + configurator Chassis comparison

Request a van →

All the types explained: Types of van body — what bodies there are and how to choose

A body for a specific chassis: Custom van bodies built to order — how an order works

Where the number comes from:How pallet capacity is calculated

Calculation

How to calculate the body volume

The volume is calculated from the internal dimensions, not the external ones: the sandwich panel takes up thickness on every side.

  1. Take the external dimensions of the body. the length, width and height over the outside — the figures given in the order
  2. Subtract two panel thicknesses from each dimension. one from each side: for length the front wall and the rear opening, for width the two side walls, for height the floor and the roof
  3. Multiply the internal dimensions. the result in metres gives the volume in m³; rounded to one decimal place
Dry freight body, 25 mm panelexternal 4,200 × 2,100 × 2,100 mm → internal 4,150 × 2,050 × 2,050 mm → 17.4 m³. Multiplying the external figures would give 18.5 m³ — 6 % too high.
Reefer, 100 mm panelexternal 5,200 × 2,250 × 2,400 mm → internal 5,000 × 2,050 × 2,200 mm → 22.6 m³. Multiplying the external figures would give 28 m³ — almost a quarter too high.

In the calculation a 100 mm panel counts as 104 mm — the lining is added to the sandwich panel. The wording “volume by external dimensions” will not do: a buyer reads it as usable volume.

FAQ

How do I work out the cubic capacity of a body?
Cubic capacity is simply the internal volume in cubic metres: multiply the internal length, width and height in metres. Internal dimensions are smaller than external ones by two wall thicknesses: 25 mm per side on a dry freight body, 50, 80 or 100 mm on an insulated or refrigerated one. The calculator above works it out for you.
How many pallets fit in a GAZelle?
A standard 3.2 m body 2 m wide holds 4 europallets 1200×800 in one tier; a long 4.2 m body 2.2 m wide holds up to 8 with mixed layout (lengthwise + crosswise row). An exact calculation for your sizes is in the calculator above.
How to calculate how many pallets fit in a van?
Take the body's inner dimensions (outer minus two sandwich-panel thicknesses), divide by the pallet size in two orientations and compare layouts — the COND calculator does this automatically, including mixed lengthwise and crosswise rows, and draws a 2D and 3D layout.
What are the sizes of europallets and other pallets?
A europallet (EUR/EPAL) is 1200×800 mm, Finnish 1200×1000 mm, American 1200×1200 mm, Asian 1100×1100 mm, container 1140×1140 mm. All types are in the calculator.
How does this calculator differ from a truck loading calculator?
Logistics calculators compute the loading of a finished body. The COND configurator solves the reverse task — it sizes the body for the required number of pallets, accounting for the actual sandwich-panel thickness (floor, walls, roof), a mode from 0 to −20 °C and the chassis mounting length. From the result we build the van right away in Almaty.
What body length do you need for 6, 8 or 10 europallets?
Guidelines at 2.2–2.3 m width: 6 pallets — body from 3.6 m, 8 — from 4.2 m, 10 — from 5.2 m. For freezing, add allowance for an 80–100 mm panel. Check your option in the calculator above.
How many pallets fit in a JAC?
A JAC N56 with a 4.2–5.2 m body takes 8–10 europallets, a JAC N90 (body up to 6.2 m) up to 15, a JAC N120 (up to 7.5 m) up to 18 in one tier. The exact figure depends on body width and panel thickness — check the calculator.
How many pallets fit in a HINO?
A HINO 300 with a 4.2–5.2 m body holds 8–10 europallets, a HINO 500 with a 7.5–8.2 m body holds 18–20 in one tier at 2.55–2.6 m width.
How to calculate loading with boxes?
For boxes the starting point is inner volume: the calculator computes it from the body's inner dimensions. Practical box loading is 80–90 percent of volume (gaps and row tying). Divide the usable volume by the box volume to get capacity.
Which body holds the most?
Maximum single-tier capacity is in bodies 2.5–2.6 m wide: at 7.5 m length 18 europallets fit, at 8.2 m — 20. But first check the chassis payload: 20 pallets at 500 kg each is already 10 tonnes.
Will the body fit my chassis?
COND fits bodies on any chassis: GAZelle, JAC, KIA, Hyundai, FAW, Hino, Isuzu, KamAZ and others. Installation follows the manufacturer's guidelines — the factory chassis warranty is preserved.
How is the body volume of a GAZelle calculated?
From the internal dimensions. On a GAZelle Next with a 4.2 m body the external dimensions are 4,200 × 2,100 × 2,100 mm and the dry freight panel is 25 mm: 4,150 × 2,050 × 2,050 mm remain inside, that is 17.4 m³. If the same body is built isothermal with a 100 mm panel, the internal volume drops to about 15 m³ — the volume is recalculated for each thickness.
Why is volume by external dimensions not suitable?
Because the panel takes thickness from every side, including the floor and the roof. On a dry freight body with a 25 mm panel the difference is about 6 %; on a reefer with a 100 mm panel it is almost a quarter of the volume. A buyer reads “volume” as usable volume and, going by external dimensions, gets a smaller body than expected.
Is a 100 mm panel exactly 100 mm in the calculation?
The calculation uses 104 mm: the lining is added to the sandwich panel. On a 6-metre body that is about another 1 cm in each dimension — little effect on volume, but it can affect the pallet layout across the width.