Truck pack optimization for LED video walls is the systematic process of calculating touring case volumes, planning loading sequences, and maximizing cargo space utilization while maintaining safe weight distribution across vehicle axles. A properly optimized truck pack reduces load-in time by 40-60%, prevents equipment damage during transport, and ensures compliance with DOT weight regulations—which impose fines of $1,000-$16,000 for overweight violations.
Anyone who's loaded a truck at 3am after a show knows the feeling: staring at a pile of cases that definitely fit on the way in, wondering why they won't fit now. Efficient truck packing isn't about luck or spatial intuition—it's about math, planning, and executing a loading strategy before you ever arrive on site.
For LED video wall deployments, the stakes are higher. A single touring case loaded with six 500mm panels weighs approximately 95kg (209lbs). A 100-panel wall requires 15-20 cases totaling 1,500-2,000kg (3,300-4,400lbs) before adding cables, processors, or rigging hardware. A poorly planned truck pack leads to damaged panels, exhausted crews, delayed load-ins, and blown budgets.
This guide provides the specific dimensions, formulas, and strategies you need to optimize truck packing for any LED wall configuration. Use our LED Wall Calculator to automatically calculate case counts and truck space requirements for your next project.
The 15-Minute Rule
If you're not calculating your truck pack before the show, you're gambling with your schedule. The difference between a 15-minute load-out and a 2-hour struggle is knowing exactly where every case goes—before it comes off the wall.
Understanding Touring Case Dimensions
LED panels ship in standardized case configurations. Knowing exact dimensions and weights is critical for accurate truck pack calculations. Here are the industry-standard touring case specifications used by major manufacturers:
Standard Panel Case Configurations
| Case Type | External Dimensions (L×W×H) | Volume | Panels | Loaded Weight |
|---|---|---|---|---|
| 4-Pack Dolly | 1100mm x 600mm x 550mm | 0.36m3 | 4 | 65-75kg (143-165lbs) |
| 6-Pack Dolly | 1200mm x 650mm x 600mm | 0.47m3 | 6 | 90-100kg (198-220lbs) |
| 8-Pack Dolly | 1200mm x 800mm x 700mm | 0.67m3 | 8 | 115-130kg (254-287lbs) |
| 12-Pack Stack | 1300mm x 700mm x 900mm | 0.82m3 | 12 | 160-180kg (353-397lbs) |
| Pre-Rigged Frame | 1500mm x 900mm x 400mm | 0.54m3 | 2-6 | 50-85kg (110-187lbs) |
📦 Dolly Cases (Wheel Cases)
- - Built-in 100mm casters for rolling
- - Wheel height adds 100-120mm to total
- - Recessed handles for stacking
- - Max stack: 2 cases (weight dependent)
- - Best for: ground transport, venues with elevators
🧊 Stack Cases (No Wheels)
- - Flat bottom with ball corners
- - Designed for 3-4 case stacking
- - More efficient truck packing
- - Requires dolly or forklift for moving
- - Best for: tours, permanent installs
Accessory Case Dimensions
Don't forget to account for support equipment cases. These typically add 15-25% to your total case volume and weight:
| Case Contents | Typical Dimensions | Loaded Weight |
|---|---|---|
| Power Cable Trunk | 1200mm x 600mm x 500mm | 45-60kg |
| Data Cable Case | 800mm x 500mm x 400mm | 25-35kg |
| Processor Rack (4U) | 600mm x 600mm x 350mm | 35-50kg |
| Rigging Hardware | 800mm x 600mm x 400mm | 50-75kg |
| Spare Parts Kit | 600mm x 400mm x 300mm | 15-25kg |
The 20% Rule for Accessories
For every LED wall deployment, budget an additional 20% of your panel case volume for accessories. A 72-panel wall with 12 panel cases needs approximately 3-4 accessory cases for cables, processing, and hardware. View our complete touring equipment reference for detailed case specifications.
Truck Capacity Fundamentals
Understanding truck dimensions and weight limits is essential for accurate pack planning. Cargo space varies significantly between vehicle types—from a Mercedes Sprinter for small corporate gigs to a 53-foot semi-trailer for stadium tours.
Vehicle Cargo Dimensions Reference
| Vehicle Type | Cargo Dimensions (L×W×H) | Volume | Payload Capacity | Use Case |
|---|---|---|---|---|
| Sprinter Van (170" WB) | 12'×5'×4.5' (3.7m×1.5m×1.4m) | 270 ft3 (7.6m3) | 3,500 lbs (1,590kg) | 8-24 panels, small corporate |
| 16' Box Truck | 16'×7'×7' (4.9m×2.1m×2.1m) | 784 ft3 (22m3) | 6,000 lbs (2,720kg) | 24-48 panels, mid-size events |
| 26' Box Truck | 26'×8'×8' (7.9m×2.4m×2.4m) | 1,664 ft3 (47m3) | 10,000 lbs (4,540kg) | 48-100 panels, most events |
| 48' Semi Trailer | 48'×8.5'×9' (14.6m×2.6m×2.7m) | 3,672 ft3 (104m3) | 44,000 lbs (20,000kg) | 100-200 panels, touring |
| 53' Semi Trailer | 53'×8.5'×9' (16.2m×2.6m×2.7m) | 4,050 ft3 (115m3) | 45,000 lbs (20,400kg) | 200+ panels, large touring |
Truck Capacity Formulas
Use these formulas to calculate whether your gear fits before booking transport:
Total Case Volume = (L × W × H) × Case Count
Usable Truck Volume = Truck Volume × 0.85
Fit Check = Total Case Volume ≤ Usable Truck Volume
Total Weight = Σ(Case Weight × Case Count)
Safe Payload = Truck Payload × 0.90
Weight Check = Total Weight ≤ Safe Payload
Panel Cases: 12 × 0.47m3 = 5.64m3
Accessory Cases: 4 × 0.25m3 = 1.00m3
Total Volume: 6.64m3 → Usable: 47m3 × 0.85 = 40m3 FITS
Total Weight: (12 × 95kg) + (4 × 50kg) = 1,340kg
Safe Payload: 4,540kg × 0.90 = 4,086kg PASSES
DOT Weight Regulations
Federal DOT regulations apply to all commercial vehicles on US interstate highways. Exceeding these limits results in fines, mandatory unloading, and potential out-of-service orders:
Single Axle Limit
Maximum per individual axle
Tandem Axle Limit
Two axles within 40-96"
Gross Vehicle Weight
Total vehicle + cargo
Overweight Fines: $100-$16,000+
DOT fines start at $100 per 1,000 lbs overweight and escalate rapidly. Vehicles exceeding limits by 10,000+ lbs face fines of $1,000-$16,000 depending on state. Some states also charge per-mile fees for overweight distance traveled. Always weigh your loaded truck at a CAT scale before long hauls.
Loading Patterns & Strategies
Efficient truck packing is about more than fitting cases—it's about load order, accessibility, and preventing damage during transport.
1. Last On, First Off (LOFO)
Load in reverse order of setup. LED panels typically go in first (back of truck) since they're built after truss and rigging. Processor cases go near the door for quick access.
2. Heavy Bottom, Light Top
Stack cases with heavy items (loaded panel cases) on the bottom. Cable cases and lighter accessories go on top. Maximum stack height: 2-3 cases depending on weight.
3. Create Lanes, Not Walls
Leave access lanes between case rows. You don't want to unload the entire truck to reach one case. Plan your pack with retrieval in mind.
4. Wheels to the Walls
Position dolly cases with wheels facing truck walls. This prevents rolling during transport and allows the flat side to face the loading area.
5. Fill the Gaps
Use soft bags, cable bundles, and small cases to fill gaps between larger cases. This prevents shifting and maximizes space utilization.
Pro Tip: Photo Documentation
Take photos of your truck pack before departure. On multi-city tours, this becomes your reference guide. What took 30 minutes to figure out once shouldn't take 30 minutes every night.
Weight Distribution & Safety
Weight matters as much as volume. Improper weight distribution causes handling issues, accelerated tire wear, and in extreme cases, accidents.
Weight over front axle
For box trucks
Weight over rear axle
For box trucks
Keep CoG low & centered
For trailers
Cable Cases (2): 2 × 45kg = 90kg
Processor Case (1): 1 × 35kg = 35kg
Hardware Case (1): 1 × 50kg = 50kg
// Plus truss, motors, control, crew gear...
Never Exceed Axle Weight Limits
Overloaded axles are illegal and dangerous. Know your truck's GAWR (Gross Axle Weight Rating) and GVWR (Gross Vehicle Weight Rating). DOT weigh stations can and will fine you—sometimes in the thousands.
Case Manifest Planning
A proper case manifest is your insurance policy. It helps track inventory, speeds up load-in/out, and provides documentation for loss or damage claims.
Manifest Should Include:
Per Case:
- • Case ID/barcode number
- • Contents (panel model, qty)
- • Empty weight vs loaded weight
- • External dimensions (L×W×H)
- • Case type (dolly/stack/frame)
Per Truck:
- • Total case count
- • Total weight
- • Loading diagram/position map
- • Driver contact info
- • Departure/arrival times
Digital Manifests Save Time
Use a digital manifest system or spreadsheet that syncs across devices. When a case is loaded, mark it off. When it arrives, verify the count. Show Tech Pro generates case manifests automatically with your calculations.
Common Packing Mistakes
Forgetting About Return Trip
Your truck pack worked perfectly for load-in. But after the show, you have tired crew, rental returns, and possibly different gear. Plan your pack to work both directions—leave space for consumables you won't have on the return.
Stacking Incompatible Cases
Not all cases stack safely. Check manufacturer ratings. A typical dolly case can support 1-2 additional cases of similar weight. Exceeding this damages lids, latches, and potentially the panels inside.
Ignoring Ramp and Door Clearance
Your cases fit in the truck, but will they fit through the venue door? Or up the loading ramp? Always check venue dock specs. Many theaters have surprisingly narrow load-in paths.
No Contingency Space
Packing to 100% capacity leaves no room for last-minute additions, backup equipment, or crew luggage. Aim for 85-90% utilization max.
Multi-Truck Tours: Splitting Gear Across Vehicles
Large LED deployments often exceed single-truck capacity. A 50-panel ROE Visual BP2V2 wall requires approximately 9 touring cases for panels alone—before adding processors, cables, rigging, and support equipment. Strategic splitting across multiple vehicles requires careful planning.
Up to 30 panels
Small corporate events, breakout sessions, 4K displays up to 16'×9'
30-80 panels
Concert touring, broadcast studios, 24'×13' to 32'×18' walls
80+ panels
Stadium shows, festivals, multiple wall configurations, large-format IMAG
Multi-Truck Organization Strategies
Department-Based Split
Truck 1: All LED panels and frames. Truck 2: Rigging, processors, cables, and support. Best for shows where LED and rigging crews work in parallel.
Wall Section Split
Truck 1: Stage left wall + its cables/processor. Truck 2: Stage right wall + its cables/processor. Best for festivals with multiple stages or when trucks arrive at different times.
Critical Path Priority
Truck 1 (arrives first): Ground support, first row of panels, all processors. Truck 2: Remaining panels, cables, spares. Lets rigging start before all gear arrives.
Multi-Stop Tour Planning
For tours with multiple stops, consider which truck arrives first at each venue. If Truck 2 always arrives 2 hours after Truck 1, ensure Truck 1 carries everything needed to start the rig. Label cases by truck assignment with colored tape or stickers.
Frequently Asked Questions
How many touring cases fit in a 26-foot box truck?
A 26-foot box truck provides approximately 1,664 cubic feet of cargo space (26'×8'×8'). Standard 6-pack touring cases (44"×26"×32") occupy roughly 21 cubic feet each. At 90% utilization, expect to fit 70-75 standard cases, though actual capacity depends on case dimensions and stacking configuration.
What are DOT axle weight limits for commercial trucks?
Federal DOT limits: single axle 20,000 lbs, tandem axle (two axles within 40-96 inches) 34,000 lbs, and gross vehicle weight 80,000 lbs on interstate highways. State limits may be more restrictive. Exceeding these limits results in fines starting at $100 per 1,000 lbs overweight, plus potential out-of-service orders.
How do I calculate truck volume requirements?
Calculate total case volume: (Case Length × Width × Height) × Number of Cases. Convert to cubic feet (divide by 1,728 if using inches). Multiply truck cargo dimensions (L×W×H) for available space. Aim for 85-90% utilization to account for irregular shapes and access lanes. Formula: Usable Space = Truck Volume × 0.85.
Should I use dolly cases or stackable cases for LED panels?
Dolly cases offer easier handling and protection for frequent transport, ideal for touring. Stackable (non-wheeled) cases maximize vertical space utilization in trucks. Many rental houses use dolly cases for panels (frequent handling) and stackable cases for cables and accessories. Consider your venue access— dollies struggle on stairs and rough surfaces.
How much contingency space should I leave in the truck?
Reserve 10-15% of truck capacity for contingency. This accommodates last-minute additions (backup panels, extra cables, client-requested equipment), crew personal gear, and consumables that won't return (used gaffer tape, cable ties). For multi-date tours, contingency space becomes essential for accumulating items throughout the run.
What causes LED panel damage during transport?
Primary causes: inadequate padding between panels (use foam dividers), exceeding case stacking limits (check manufacturer specs), shifting during transport (use ratchet straps every 2-3 cases), temperature extremes (avoid direct sunlight in summer), and moisture (climate-controlled trucks for long hauls). Damaged panels typically show dead pixels, connector issues, or cabinet warping.
How do I plan truck packs for multi-stop tours?
Create a "standard pack" diagram that works for all venues. Load consistently every night using the same pattern. Photograph your pack before departure. For multi-truck tours, assign cases to specific trucks with colored labels. Consider venue-specific needs (some venues may need certain gear first) and adjust arrival times rather than pack order when possible.
What tools help calculate LED truck pack requirements?
Dedicated LED calculators like Show Tech's LED calculator automatically compute panel counts, case requirements, and total weights based on your wall dimensions. This eliminates manual calculations and ensures accurate truck planning. Spreadsheets work for simple deployments but lack real-time panel database updates and case configuration options.