Van Capacity Summary

This is the definitive answer to transporting 8 x 4 (2440 x1220mm) 2mm Correx in the UK's most popular trade vans.

Each week, tradespeople ask Google questions like:

• Will 8 × 4 Correx fit in my Transit Custom?

• How many sheets can I safely carry?

• Will I run out of payload before I run out of space?

• Is it worth collecting Correx myself or having it delivered?

• Which van is best for carrying floor protection?

Most of the answers online are guesswork or anecdotal. 

We decided to sharpen our pencils, get our abacus ready, and boot up the old calculator to give you the proper guidance.

Using published manufacturer dimensions, standard UK trade specifications for 2440 × 1220 × 2mm Correx protection boards, and practical loading assumptions, we've calculated the theoretical carrying capacity of the UK's most popular medium vans.

Whether you're a decorator carrying 30 sheets or a contractor buying by the pallet, this guide explains the maths behind transporting Correx efficiently.

The Maths Behind Every Calculation

All calculations in this guide use the same engineering assumptions.

Standard Correx Board

Specification	Value
Board size	2440 × 1220 mm (8 × 4 ft)
Thickness	2 mm
Area	2.9768 m²
Weight	1.10 kg
Factory pack	50 sheets
Factory pack weight	55 kg
Factory pack height	100 mm

Vehicle Assumptions

To make every van directly comparable we assumed:

• Standard 9 mm ply lining (18 mm total width reduction)

• 200 mm roof clearance for safe loading

• Driver, passenger and fuel allowance already deducted

• Maximum usable payload limited to approximately 1,000 kg

• Boards loaded perfectly flat

These assumptions create a realistic comparison rather than an absolute laboratory maximum.

The Correx Van Capacity Index™

Van	Max Sheets	50-Sheet Packs	Weight	Width Clearance	Loading Difficulty	Everyday Trade Load*
Ford Transit Custom	616	12	678 kg	172 mm	⭐ Easy	50–150 sheets
Volkswagen Transporter	605	12	666 kg	24 mm	⚠ Precision loading	40–120 sheets
Vauxhall Vivaro	598	11	658 kg	38 mm	Moderate	50–140 sheets
Renault Trafic	593	11	652 kg	48 mm	Moderate	50–140 sheets

*The "Everyday Trade Load" is our practical recommendation. While the engineering capacity represents the maximum theoretical number of sheets that can be carried using the assumptions above, most contractors also need space for tools, consumables, waste materials and safe access within the load area.

** Of course, we've seen some crazy things - like sheets on the passenger side, or tied under, we'll leave that to the Instagram reels and focus on the facts.

What We Learned

Perhaps the biggest surprise?

None of these vans run out of payload before they run out of space.

With 2mm Correx weighing only around 1.10 kg per sheet, every van in this comparison is volume-limited rather than weight-limited.

That means your biggest challenge isn't weight.  It's organising the load efficiently.

Ford Transit Custom

Verdict

★★★★★ Our overall winner

Maximum Engineering Capacity

• 616 sheets

• 12 factory packs

• 677.6 kg

Why It Wins

The Transit Custom provides an effective width of 1,392 mm between the ply-lined wheel arches, leaving 172 mm of clearance around a standard 1220 mm-wide Correx sheet.

That generous margin makes loading easier, reduces the risk of damaging sheet edges and allows faster one-person handling compared with tighter load bays.

Everyday Recommendation

Although the van can theoretically carry more than 600 sheets, most decorators, kitchen installers and refurbishment contractors are likely to benefit from carrying 50–150 sheets and using the remaining space for tools and equipment.

For larger projects, ordering additional boards directly to site is often more efficient than filling the van to capacity.

Official Vehicle Information

Ford Transit Custom specifications:  Ford Transit Custom

Vehicle dimensions: Ford dimensions guide

Volkswagen Transporter

Verdict

★★★★☆

Maximum Engineering Capacity

• 605 sheets

• 12 factory packs

• 665.5 kg

The Interesting Part

The Transporter can carry almost exactly the same number of sheets as the Transit Custom.

The difference is loading.

With only 24 mm of clearance between the wheel arches and a standard Correx sheet, loading requires much greater precision.

Small misalignments are more likely to catch on ply lining, increasing friction during loading and unloading.

Everyday Recommendation

Carry 40–120 sheets for daily work and use direct-to-site delivery for larger refurbishment projects.

Official Vehicle Information

Volkswagen Transporter specifications

Renault Trafic

Verdict

★★★★☆

Maximum Engineering Capacity

• 593 sheets

• 11 factory packs

• 652.3 kg

The Trafic offers a more forgiving loading experience than the Transporter thanks to its 48 mm clearance.

While slightly lower in overall capacity, the difference is unlikely to matter for day-to-day trade work.

Recommended working stock:

50–140 sheets

Official specifications:

Renault Trafic dimension

Vauxhall Vivaro

Verdict

★★★★☆

Maximum Engineering Capacity

• 598 sheets

• 11 factory packs

• 657.8 kg

The Vivaro sits neatly between the Trafic and Transporter.

Its 38 mm loading clearance means careful loading is worthwhile, but it's still very practical for contractors transporting protection boards regularly.

Recommended working stock:

50–140 sheets

Official specifications:

Vauxhall Commercial Vehicles

Fun Correx Maths

How Tall Is 100 Sheets?

Exactly 200 mm.

That's roughly the height of a cordless drill standing upright.

How Heavy Is One Factory Pack?

One standard pack weighs approximately 55 kg.

That's about the same as carrying:

• one bag of cement plus a toolbox

• or two medium-sized kitchen appliances

How Much Does 300 Sheets Weigh?

Approximately 330 kg.

That's less than four average adults.

Could You Carry a Whole Pallet?

Not quite.

A standard pallet is around 500 sheets.

That's approximately:

• 550 kg

• 1 metre high

Most medium vans can accommodate this from a weight perspective, but you still need to consider safe loading, visibility, access to tools and securing the load correctly.

What is the True Cost of Correx

Well its not just the purchasing, its the use, reuse, abuse, shipping, storage and more. You can dig into the true maths of buying floor protection here

The Surprising Statistic

A fully loaded Transit Custom carrying 616 sheets is still over 300 kg below the assumed 1,000 kg usable payload limit.

With 2mm Correx, space is the limiting factor. It's not weight.

Should You Actually Fill Your Van?

Probably not.

Although these vans are physically capable of carrying hundreds of sheets, most professional tradespeople work far more efficiently by carrying only the stock they regularly use.

In truth, you'll want to use the extra room for:

• More room for tools.

• Easier loading and unloading.

• Less risk of damaging boards.

• Better visibility and safer load management.

• Lower fuel consumption from unnecessary cargo.

• Faster access to equipment on site.

For larger refurbishment or construction projects, direct-to-site delivery is often the more economical option, allowing your van to remain organised while ensuring fresh stock arrives exactly when it's needed.

Safe Loading

The Health and Safety Executive recommends that loads are secured correctly, manual handling risks are assessed, and workplace transport is managed safely.

Further guidance can be see on HSE Manual Handling Guidance or HSE Workplace Transport Guidance

Need Correx for Your Next Project?

Whether you're carrying 25 sheets for a decorating job or ordering hundreds of boards for a refurbishment project, 2mm TI-Pro® Protective Boards are designed for professional use and are available with free next working day delivery across most of the UK.

Rather than filling your van with months of stock, many contractors choose to keep an everyday working load and top up as projects require.

Explore our range of TI-Pro® Protective Boards: