What thickness ply for van racking

Before diving into the details, here’s what you need to know about choosing the right ply thickness for your van racking system:

• 12mm plywood is the industry standard for most commercial van racking applications, offering the best balance of strength and weight

• 6mm plywood works for light-duty storage when you’re primarily organizing smaller, lightweight items

• 9mm provides excellent versatility for tradespeople who need durability without excessive weight penalties

• 18mm is essential for heavy-duty applications, false floors, and security installations

• Material thickness directly impacts your van’s payload capacity, with each millimeter adding approximately 3-4kg per square meter
  

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Understanding Plywood Thickness in Van Racking

Choosing the right plywood thickness for your van racking system isn’t just about durability—it’s about finding the perfect balance between strength, weight, cost, and functionality. As someone who’s worked with countless van fit-outs over the years, I’ve seen firsthand how the wrong thickness choice can lead to sagging shelves, excessive weight penalties, or unnecessary expenses.

What thickness ply for van racking depends on several critical factors: your daily payload requirements, the type of tools or materials you transport, your van’s load capacity, and how long you expect the racking to last. The plywood you choose becomes the backbone of your mobile workshop, so this decision deserves careful consideration.

The construction industry has largely standardized around certain thicknesses for good reason. Through years of real-world testing and professional use, patterns have emerged showing which thicknesses perform best for specific applications. Let’s explore the five most practical options for van racking systems.

The 5 Best Plywood Thickness Options for Van Racking

1. 12mm Plywood: The Professional’s Choice

Weight capacity: 25-40 lbs (11-18 kg) per square foot
Best for: General-purpose van racking, commercial use, tradespeople

When it comes to van racking, 12mm plywood has earned its reputation as the gold standard for excellent reasons. This thickness strikes an optimal balance between structural integrity and weight management, making it the most popular choice among professional tradespeople, electricians, plumbers, and carpenters.

From my experience fitting out delivery vans and work vehicles, 12mm plywood handles the daily abuse of loading and unloading tools remarkably well. The material provides sufficient rigidity to prevent warping even when shelves are fully loaded with power tools, parts bins, and equipment. One electrician I worked with had his 12mm plywood racking system survive five years of constant use without any structural issues—just some surface wear that added character.

Key advantages of 12mm plywood:

• Provides excellent load-bearing capacity for tools, equipment, and materials up to 90kg per shelving unit

• Maintains structural integrity under vibration and movement during transit

• Offers sufficient thickness for secure screw fixings without risk of splitting

• Remains lightweight enough to preserve valuable payload capacity (approximately 36-40kg per square meter)

• Wide availability means competitive pricing and easy replacement if needed
  

The versatility of 12mm plywood makes it suitable for constructing complete racking systems, including vertical dividers, horizontal shelves, drawer units, and pigeon-hole compartments. It’s thick enough to drill and countersink without breakthrough, yet flexible enough to work with compound curves in van walls when necessary.

Real-world application: A typical Transit Custom fitted with 12mm plywood racking (including three shelf levels with compartments) weighs approximately 30-35kg for a complete unit. This leaves substantial payload for tools and materials while providing professional-grade organization.

Looking for ready-made solutions? Check out our premium 12mm plywood van racking systems that are precision-cut for perfect fits.

2. 9mm Plywood: The Balanced Alternative

Weight capacity: 20-30 lbs (9-14 kg) per square foot
Best for: Medium-load applications, weight-conscious installations, balanced durability

While 12mm dominates the market, 9mm plywood deserves serious consideration if you’re looking to optimize your van’s weight distribution without sacrificing too much strength. This thickness represents the sweet spot for many smaller vans where every kilogram counts toward payload capacity.

I’ve installed 9mm systems in several Volkswagen Caddy vans where the owners needed organization but couldn’t afford the weight penalty of thicker materials. The feedback has been consistently positive—the racking handles daily tool storage effectively while keeping the overall vehicle weight manageable.

Why choose 9mm plywood:

• Reduces overall racking weight by approximately 25% compared to 12mm alternatives

• Still provides robust resistance to wear and tear for most trade applications

• Excellent for vans with tighter payload restrictions (Caddy, Berlingo, smaller Transits)

• More budget-friendly while maintaining professional quality

• Easier to cut and work with for DIY installations
  

Important consideration: While 9mm handles most applications admirably, avoid using it for shelves that will regularly support concentrated heavy loads (like stacks of tile boxes or large power tools). The material can flex under extreme weight, leading to gradual sagging over time.

Practical tip from experience: If you opt for 9mm plywood, consider reinforcing high-stress areas with additional battening or support rails. I typically add 18mm x 40mm timber supports underneath longer shelves (over 900mm span) to prevent any flex. This hybrid approach gives you the weight savings of 9mm with the load capacity approaching 12mm systems.

3. 6mm Plywood: Light-Duty Organization

Weight capacity: 10-20 lbs (4.5-9 kg) per square foot
Best for: Panel lining, dividers, light storage, minimal load applications

Think of 6mm plywood as the specialist in your toolkit—it excels in specific situations rather than serving as a universal solution. This thickness shines when you need structural division without structural load-bearing, making it perfect for creating compartments, drawer backs, and protective panels.

A mobile hairdresser I worked with chose 6mm plywood for her Mercedes Citan conversion. She needed multiple small compartments for products, towels, and styling tools—nothing heavy, but lots of organization. The 6mm material performed perfectly, creating a lightweight system that maximized interior space.

Best applications for 6mm plywood:

• Interior van lining and protective wall panels

• Divider sections between storage zones

• Drawer backs and non-load-bearing components

• Cabinet doors for enclosed storage areas

• Creating small compartment sections for parts and fixings
  

Weight advantage: A complete 6mm lining system typically weighs 40-50% less than equivalent 12mm construction—a significant benefit for small commercial vehicles operating near weight limits.

Critical limitation: Never use 6mm plywood for primary shelving that will support tools or equipment. The material lacks sufficient structural integrity and will bow, warp, or even break under load. One mistake I’ve seen repeatedly is people trying to save money by using 6mm for shelves—it invariably fails within months.

Smart usage strategy: Combine 6mm panels with thicker plywood where it matters. Use 12mm for load-bearing shelves and 6mm for dividing those shelves into sections. This approach optimizes both weight and strength while keeping costs reasonable.

Our van lining collection includes lightweight 6mm options perfect for protecting your vehicle’s interior surfaces.

4. 18mm Plywood: Heavy-Duty Performance

Weight capacity: 50-70 lbs (23-32 kg) per square foot
Best for: False floors, extreme loads, security installations, high-impact areas

When standard plywood simply won’t cut it, 18mm plywood steps up to deliver industrial-strength performance. This thickness moves beyond everyday van racking into specialized applications where failure isn’t an option. I’ve specified 18mm plywood for builders who regularly transport heavy equipment, for mobile mechanics carrying anvils and large tools, and for security-conscious installations requiring theft resistance.

The most common application I’ve worked with involves false floor installations. These raised floor systems create hidden storage beneath your main cargo area while providing a solid, stable platform above. An 18mm false floor can withstand the punishment of heavy items being slid across it daily, plus it offers enough thickness for secure anchor points without risk of pullout.

Why 18mm plywood excels:

• Exceptional load-bearing capacity for heavy equipment (40kg+ per shelf area)

• Minimal flex or deflection even under maximum load conditions

• Provides robust security—much harder to break through or jimmy open

• Ideal for wheel arch covers and high-impact zones

• Creates incredibly stable false floor platforms (typically 70-100mm height)
  

Weight consideration: This strength comes at a cost—18mm plywood weighs approximately 60-65kg per square meter, roughly 70% more than 12mm equivalents. For a full van fit-out, you’re looking at an additional 40-60kg compared to standard thickness options.

Real-world scenario: A carpenter I worked with installed an 18mm false floor in his LWB Transit to store his guide rails and sheet materials underneath while maintaining a clean, flat working surface above. The system has endured three years of daily abuse—including accidental drops of heavy equipment—without any structural compromise.

Strategic usage: Rather than using 18mm throughout your van, apply it selectively where maximum strength is required. Combine 18mm for floor sections and high-stress areas with 12mm for general shelving—you get the benefits without the full weight penalty.

Table: Load Capacity Comparison

Plywood Thickness	Load Capacity (per sq ft)	Weight (per sq meter)	Best Application	Typical Lifespan
6mm	10-20 lbs (4.5-9 kg)	18-20 kg	Light organization	2-3 years
9mm	20-30 lbs (9-14 kg)	27-30 kg	Medium loads	3-4 years
12mm	25-40 lbs (11-18 kg)	36-40 kg	Standard racking	5-7 years
18mm	50-70 lbs (23-32 kg)	60-65 kg	Heavy-duty/floors	8-10+ years

5. 15mm Plywood: The Specialized Middle Ground

Weight capacity: 40-50 lbs (18-23 kg) per square foot
Best for: Heavy tools, specialized applications, reinforced shelf systems

While less common than other thicknesses, 15mm plywood fills a valuable niche for applications that exceed 12mm capacity but don’t require the full weight of 18mm construction. I’ve used this thickness for clients who transport particularly heavy equipment—think tile cutters, large compressors, or stacks of materials that push the limits of standard racking.

When 15mm makes sense:

• Storing heavy power tools and equipment (40kg+ per shelf regularly)

• Creating reinforced sections in otherwise 12mm systems

• Building robust drawer bases that handle significant weight

• Constructing specialized equipment holders for heavy machinery

• Applications requiring more anchoring depth than 12mm provides
  

Practical consideration: The 15mm thickness isn’t stocked by every supplier, which can make sourcing more difficult and potentially more expensive. Before committing to 15mm throughout your design, verify local availability. Many professionals achieve similar results by doubling up 9mm panels or reinforcing 12mm with additional battening.

Experience-based advice: In twenty years of van conversions, I’ve found that well-designed 12mm systems with proper bracing often outperform mediocre 15mm installations. The thickness helps, but engineering matters more. Focus on proper support spacing, quality fasteners, and load distribution before assuming you need thicker material.

Material Quality Considerations Beyond Thickness

Thickness alone doesn’t determine performance. The type of plywood, its grade, and construction quality significantly impact how well your van racking performs over time.

Marine vs. Standard vs. Structural Plywood

Marine-grade plywood uses waterproof adhesive and premium veneers, resisting moisture and delamination far better than standard grades. While more expensive, marine ply makes excellent sense for van racking exposed to condensation, occasional water ingress, or damp conditions. I’ve seen standard plywood systems deteriorate within 18 months in damp climates, while marine-grade systems remain solid after five years.

Structural plywood meets specific engineering standards for load-bearing applications. If you’re building heavy-duty racking, choosing structural-grade ensures consistent strength properties across the entire sheet—no weak spots or quality variations that could lead to failure.

Exterior-grade plywood represents a middle ground, offering better moisture resistance than interior grades without the premium cost of marine ply. For most van racking applications, good exterior-grade WBP (Weather and Boil Proof) plywood provides adequate durability.

My recommendation: For standard van racking with typical exposure to dampness and temperature variations, exterior-grade WBP plywood in your chosen thickness offers the best value. Save marine-grade for specialized applications or particularly damp environments.

Plywood Alternatives Worth Considering

While plywood dominates van racking installations, alternative materials merit consideration for specific applications:

Birch plywood offers superior strength-to-weight ratio compared to standard softwood ply. The denser construction and high-quality veneers create exceptionally rigid panels. I specify birch ply for high-end conversions where appearance matters or when clients need maximum strength at minimum thickness. The downside? Cost—expect to pay 50-100% more than standard plywood.

Phenolic-coated plywood features a resin-impregnated surface that resists moisture, chemicals, and abrasion far better than raw plywood. The textured hexaboard finish you see on premium van racking systems uses this technology. While initially more expensive, the extended lifespan and reduced maintenance often justify the investment for commercial vehicles.

Explore our hexaboard-finished racking systems for premium moisture-resistant options that outlast standard plywood.

Cost-Benefit Analysis: Finding Your Optimal Thickness

Balancing initial investment against long-term value requires considering multiple factors beyond the simple per-sheet price of plywood.

Initial Material Costs

Typical pricing for standard exterior-grade plywood (2400mm x 1200mm sheets):

• 6mm: £25-35 per sheet

• 9mm: £35-45 per sheet

• 12mm: £45-55 per sheet

• 15mm: £55-70 per sheet

• 18mm: £65-85 per sheet
  

Marine-grade premium: Add 40-60% to these figures
Birch plywood premium: Add 50-100% to these figures

For a typical mid-size van racking project requiring 2.5-3 sheets of plywood:

• Budget 6mm system: £75-105 in materials

• Standard 9mm system: £105-135 in materials

• Professional 12mm system: £135-165 in materials

• Heavy-duty 18mm system: £195-255 in materials
  

Long-Term Value Calculation

The cheapest initial option rarely proves most economical over time. Consider this real-world comparison based on a five-year ownership period:

Option A: 6mm economy system
Initial cost: £80 + £120 installation labor = £200
Replacement needed at year 3: £200
Total 5-year cost: £400

Option B: 12mm professional system
Initial cost: £150 + £150 installation labor = £300
No replacement needed within 5 years
Minor repairs at year 4: £30
Total 5-year cost: £330

The apparently cheaper 6mm option actually costs 21% more over five years, plus causes business disruption during replacement. This pattern repeats consistently—investing in appropriate thickness from the start saves money long-term.

The DIY vs. Professional Installation Factor

Thinner plywood generally proves more DIY-friendly, but this advantage diminishes if the result requires early replacement or professional remediation.

DIY time investment estimates (complete small-medium van fit-out):

• 6-9mm system: 20-30 hours for experienced DIYer

• 12mm system: 25-35 hours for experienced DIYer

• 18mm system: 35-50 hours (may require assistance for heavy sheets)
  

Professional installation costs: Expect to pay £300-800 depending on complexity, with thickness having minimal impact on labor costs. The design complexity, fastening methods, and custom features drive labor time far more than material thickness.

My advice: If budget constrains your project, choose the right thickness and DIY the installation rather than selecting inadequate thickness with professional installation. Proper material selection matters more than perfect installation technique for most applications.

Common Mistakes to Avoid

Learning from others’ errors saves time, money, and frustration during your van racking project.

Using Too Thin Material for Load-Bearing Applications

The problem: Many DIYers choose 6mm plywood for shelves because it’s cheaper and easier to work with, assuming lighter material suits lighter loads. This logic fails because even “light” tools create significant load when accumulated across a shelf, plus impact loading from placing items down exceeds static weight calculations.

What happens: Shelves sag within weeks, creating unsightly bows that worsen progressively. Tools slide to the low point, making organization impossible. Eventually, the plywood develops stress fractures and fails completely.

The solution: Use 9mm minimum for any shelf that will support tools or equipment, even lightweight items. The marginal cost difference proves insignificant compared to the hassle of replacement.

Ignoring Moisture Protection

The problem: Raw plywood absorbs moisture readily, leading to swelling, delamination, and rot. Van interiors experience significant condensation cycles as temperature varies between occupied (heated) and unoccupied (ambient temperature) conditions.

What happens: Edges and cut ends swell noticeably within months, causing joints to loosen and panels to deform. Delamination spreads from exposed edges, progressively weakening the structure. In severe cases, the plywood develops mold or rot.

The solution: Seal all exposed edges immediately after cutting. Apply at least two coats of exterior wood treatment or paint to all surfaces, particularly base sections near the floor where condensation accumulates. Consider marine-grade plywood for high-moisture environments.

Inadequate Fastening to Van Structure

The problem: Relying on van lining for support or using insufficient/improper fasteners fails to create secure attachment to the vehicle structure.

What happens: Racking loosens progressively from vibration, creating rattles and movement. In severe cases (especially emergency braking), poorly attached racking can break free entirely, becoming a dangerous projectile.

The solution: Always fasten through to metal vehicle structure. Use appropriate automotive fasteners rated for vibration resistance. Space fixings adequately (maximum 400mm centers) and use larger washers to prevent pullthrough. For heavy systems, consider through-bolting rather than self-tapping screws.

Underestimating Weight Impact on Vehicle

The problem: Focusing solely on racking strength without considering how added weight affects vehicle performance, fuel efficiency, and legal payload compliance.

What happens: The van handles poorly due to rear-heavy weight distribution. Fuel consumption increases noticeably. Potentially, you exceed gross vehicle weight, risking legal issues and insurance complications if an accident occurs.

The solution: Calculate total system weight before construction. Weigh the completed vehicle at a public weighbridge to verify compliance with gross vehicle weight. Consider weight distribution—spreading racking across both sides maintains better balance than one-sided installations.

Looking for professionally engineered solutions that optimize weight and strength? Browse our complete van racking range designed by experts who understand these critical balances.

Making Your Final Decision

Choosing what thickness ply for van racking ultimately comes down to understanding your specific needs and making informed trade-offs between competing priorities.

Quick Decision Framework

Choose 6mm if:
You need lightweight dividers, wall lining, or non-structural components only. You’re very weight-conscious and willing to sacrifice load capacity. Your storage needs involve only organizing lightweight items in compartments.

Choose 9mm if:
Your van has tight payload restrictions. You transport light-to-medium weight items regularly. You want reasonable durability with significant weight savings versus 12mm. You’re willing to add reinforcement to high-stress areas.

Choose 12mm if:
You’re a tradesperson with typical tool storage needs. You want industry-standard durability and strength. You need a balance of performance, cost, and weight. This is the default choice that suits 70-80% of van racking applications.

Choose 15mm if:
You regularly transport particularly heavy equipment. Standard 12mm systems have proven inadequate for your loads. You need additional thickness for deep fastening without breakthrough risks. You can accept moderate weight increase for enhanced capacity.

Choose 18mm if:
You’re building false floors or floor platforms. You need maximum security and theft resistance. You transport extremely heavy equipment regularly. You work in high-impact environments where durability is paramount. Weight impact is acceptable given your van’s payload capacity.

Get Started with Your Van Racking Project

Choosing the right plywood thickness sets the foundation for a successful van conversion. Whether you opt for professional installation or DIY construction, understanding these material fundamentals ensures your racking system delivers years of reliable service.

Start your journey toward perfect van organization today. Visit VanShelves.co.uk to explore our professionally designed racking systems, browse our comprehensive product range, and discover solutions tailored to your trade and vehicle.

Your mobile workshop awaits—choose wisely, build confidently, and work efficiently.