On a new van, any racking, lining, ply floor, roof racks and the tools you carry all come straight off the van’s available payload. In practice, a “typical” light fit-out can reduce payload by around 80–200kg, while a heavier trade setup can easily take 250–400kg (or more) before you’ve loaded any materials.
What actually counts against payload?
Payload is the difference between the van’s Gross Vehicle Weight (GVW) and its kerb weight (the van as supplied, with fluids and usually a driver allowance). Anything you add or carry counts, including:
- Racking/shelving: often 40–120kg depending on material and coverage
- Ply lining + floor: commonly 30–70kg
- Roof rack/ladder system: roughly 20–60kg, plus the ladders themselves
- Tools and fixings: 50–200kg is very common; some setups exceed this
- Extra kit: inverters, compressors, generators, beacons, towbar, bulkhead, etc.
Why it matters (and where people get caught out)
It’s easy to buy a new small van with, say, 650–800kg payload on paper, then lose 200–300kg to fit-out and tools—leaving far less headroom for stock, waste, or a second person. Remember: passengers also count (their weight and any personal kit).
How to estimate it properly before ordering
Ask the dealer/manufacturer for the van’s exact payload for the chosen trim and options (auto gearboxes, air con packs, additional batteries, tailgates, etc. can change kerb weight). Then get the racking supplier to provide installed weights. If you want certainty, weigh your current tool setup (many public weighbridges will do this cheaply).
If you’re regularly near the limit, consider a higher-GVW variant (still drivable on a standard car licence up to 3,500kg GVW) or a lighter racking system.
