Coaming Box Dimensions and Standard Sizes: 1200x1000, 1150x985, and 1470x1150 Fully Explained
A coaming box is not a single product with a single dimension. It is a family of sleeve packs sized to the truck, pallet, and rack standards of the buyer's logistics loop. Specifying the right footprint determines how the sleeve stacks, what trucks it loads on, and whether it returns clean through the warehouse door.
Key Takeaways
- Three Joyrepak footprints cover most industrial returnable loops: 1200x1000 mm (European / global standard), 1150x985 mm (Asian / tight-tolerance truck standard), and 1470x1150 mm (oversize load carrier).
- Each footprint is available in multiple height variants, allowing the same sleeve to handle loads from 700 mm to 1600 mm tall depending on the SKU selected.
- Footprint selection is set by truck fleet and pallet standard. Height selection is set by the maximum load cube you need to enclose.
- Cross-footprint stacking does not work; mixing footprints in one warehouse creates stacking inefficiency and racking clearance problems.
- Joyrepak's R&D design team can build custom footprints between these standards when bulk load and truck conditions do not match an off-the-shelf SKU.
Table of Contents
- Why Three Standard Footprints Exist
- Footprint 1200x1000 mm — The European and Global Default
- Footprint 1150x985 mm — The Asian and Tight-Tolerance Truck Standard
- Footprint 1470x1150 mm — The Big Load Carrier for Oversize Cargo
- Height Variants Within Each Footprint
- Matching Footprint to Truck and Pallet Standards
- Sizing Checklist for Specifying a Coaming Box
This guide walks through the three standard Joyrepak big load carrier footprints in the L-GLT sleeve pack range. It maps each footprint to the truck and pallet standard it serves, shows the typical height variants available within each footprint, and finishes with a sizing checklist procurement teams can run against their own warehouse and truck plans.
Why Three Standard Footprints Exist
Industrial returnable packaging serves buyers who ship across truck fleets built to different standards. European trucks are built around the ISO 6780 1200x1000 mm pallet standard. North American GMA pallets are 1219x1016 mm (48x40 in), close to 1200x1000 but not identical. Asian-built trucks often have tighter container widths and shorter bed heights, which is why the 1150x985 mm footprint exists. And oversize-load operations (large automotive components, oversized machinery parts) need the 1470x1150 mm big load carrier footprint.
Joyrepak supports all three footprints because the company serves 2,300+ customers across North America, Europe, the Middle East, and Southeast Asia on a single SKU catalog. Standardizing on one footprint globally would force some customers to reject some of their trucks and racking for the sake of packaging consistency. The three-footprint strategy keeps each customer's truck plan intact while still delivering a single supplier relationship.
Why Footprint Selection Comes Before Height Selection
A common mistake is to pick the tallest sleeve pack because it has more load capacity. Footprint matters more than height. The footprint determines whether the sleeve nests with the lid, whether it sits correctly on the pallet base, and whether it fits the truck bed width. Height can be adapted to load cube by selecting the right SKU from the height variant ladder. Footprint, once set, locks the sleeve to a specific pallet and lid family.
Joyrepak's sizing catalog treats footprint as the primary spec and height as the secondary spec. Most L-GLT sleeve packs in the catalog are available across both the 1200x1000 and 1150x985 footprints at the same height; the 1470x1150 is a separate big load carrier family.
Footprint 1200x1000 mm — The European and Global Default
The 1200x1000 mm footprint is the default in most global logistics fleets because it matches the European standard pallet under ISO 6780 and sits within the width tolerance of most North American GMA pallets (1219x1016 mm). When a buyer specifies a Joyrepak sleeve pack with no footprint override, the engineering team will quote the 1200x1000 standard unless the truck fleet profile flags a different fit.
This footprint is the most extensively tested in Joyrepak's catalog, with more height variants and more lid options than the other two footprints. Honeycomb box and divider solutions are stocked in matching 1200x1000 dimensions for buyers who need internal cell separation.
Typical Load Capacity at 1200x1000
The 1200x1000 footprint at the standard 1000 mm sleeve height encloses a load cube of approximately 1.2 cubic meters per sleeve, depending on the lid and pallet base configuration. Stack two sleeves on a single pallet base and the effective load height doubles while the truck footprint remains 1200x1000 mm.
Payload capacity is governed by the PP honeycomb sleeve thickness and the lid specification rather than the footprint. The 1200x1000 standard sleeve typically supports 500 kg to 800 kg of payload in single-trip handling and proportionally less in stacked configurations because the lower sleeve carries both loads.
When 1200x1000 Is the Wrong Choice
Two scenarios favor a different footprint. First, when the truck fleet uses 1150x985 or other Asian-built pallet standards as the primary, the 1200x1000 sleeve leaves dead space in the truck bed and can shift during transport. Second, when the load exceeds what fits in the 1470x1150 sleeve maximum dimensions, the buyer needs an oversize carrier and not a taller version of the standard 1200x1000.
Footprint 1150x985 mm — The Asian and Tight-Tolerance Truck Standard
The 1150x985 mm footprint serves buyers with Asian-built truck fleets where container width is constrained by the truck body rather than the pallet standard. The 15 mm width difference from the 1200x1000 standard sounds small, but on a truck carrying 30 sleeve packs per layer, the cumulative gap is 450 mm of bed width that does not get used efficiently. The 1150x985 mm footprint closes that gap.
This footprint also fits tighter warehouse racking configurations where each mm of width matters. A 1150x985 sleeve nest occupies less racking clearance, allowing tighter row spacing and higher cubic density in the warehouse.
Why Joyrepak Uses 1150x985 Instead of 1100x1100
Some Asian-built sleeve pack competitors use a square 1100x1100 mm footprint because square feels intuitive. Joyrepak uses the rectangular 1150x985 mm footprint because it matches the orientation of the ISO 6780 standard pallet more closely than a square footprint does. The 1150 mm length aligns with the pallet length direction; the 985 mm width aligns with the pallet width direction. A square footprint would force the sleeve to be rotated 90 degrees on the pallet, which creates nesting problems with the lid.
Limitations of the 1150x985 Footprint
The 1150x985 footprint has slightly less load cube per sleeve than the 1200x1000 standard. The reduction is about 6 percent, so a sleeve height of 1000 mm encloses 1.13 cubic meters instead of 1.2 cubic meters. In mixed-fleet operations, the per-truck cubic loss matters; in Asian-only fleets, the savings in bed-width efficiency and racking clearance outweigh the cubic loss.
Stacking within the 1150x985 footprint family works exactly as it does for the 1200x1000 family. The lid and pallet base nest without modification. Cross-footprint stacking between 1150x985 and 1200x1000 does not work because the rim profiles do not match.
Footprint 1470x1150 mm — The Big Load Carrier for Oversize Cargo
The 1470x1150 mm footprint is the big load carrier in Joyrepak's catalog. It is reserved for cargo that exceeds the dimensions of the standard 1200x1000 sleeve pack — typically large automotive components, oversized machinery parts, and bulk loads.
This footprint requires a forklift with side-shift capability and racking clearance of at least 1480 mm between uprights. The 270 mm wider footprint compared to the 1200x1000 standard means the sleeve does not fit a standard 1200 mm wide rack bay; the buyer needs either a wider rack or dedicated floor stack areas.
Typical Use Cases for 1470x1150
Three operations favor the 1470x1150 footprint:
- Automotive powertrain assembly: engines, transmissions, and sub-assemblies that exceed the standard sleeve dimensions need a wider pack.
- Oversized machinery parts: large castings, gearbox housings, and rotating equipment that cannot fit through the 1200x1000 sleeve opening.
- Bulk food and agricultural loads: large-quantity shipments where the per-trip cube needs to be maximized and the sleeve is the cargo envelope, not the cargo organizer.
Sizing Implications
The 1470x1150 footprint increases the per-sleeve load cube by about 40 percent compared to the 1200x1000 standard. At the maximum 1600 mm sleeve height, the sleeve encloses approximately 2.7 cubic meters. Payload capacity scales with the PP honeycomb sleeve thickness and lid specification, similar to the smaller footprints.
Cross-footprint compatibility with 1200x1000 lids and pallets does not exist. The 1470x1150 family uses its own lid and pallet base series, which Joyrepak stocks separately. Buyers who mix 1470x1150 sleeves with the standard 1200x1000 fleet in the same warehouse need to keep the lid and pallet families separated.
Height Variants Within Each Footprint
Within each footprint, Joyrepak offers multiple sleeve heights to match the load cube the buyer needs to enclose. Selecting the correct height is the secondary specification after footprint selection.
Standard Height Ladder for 1200x1000
The 1200x1000 sleeve pack family is available in heights from 800 mm to 1500 mm in 100 mm or 200 mm step increments. The most common stock heights are 1000 mm, 1200 mm, and 1500 mm. Custom heights between 800 mm and 1500 mm are available from the Joyrepak factory within the standard lead time envelope.
Heights above 1500 mm require a thicker sleeve wall or internal rib reinforcement, which Joyrepak specifies as a heavy-duty variant rather than the standard SKU. Buyers who need sleeve heights above 1500 mm for tall cargo should consult the engineering team during specification rather than ordering standard SKUs.
Standard Height Ladder for 1150x985
The 1150x985 sleeve pack family is available in heights from 700 mm to 1300 mm in the standard step ladder. The 1150x985 footprint is typically used for smaller loads than the 1200x1000 family, so the height range is shorter. Custom heights are available.
Standard Height Ladder for 1470x1150
The 1470x1150 big load carrier family is available in heights from 900 mm to 1600 mm. The taller ladder accommodates the larger load cube that justified choosing the 1470x1150 footprint in the first place.
Why the Height Ladder Stays on Standard Steps
The height ladder stays on 100 mm or 200 mm steps because the rim profile, where sleeve meets sleeve during stacking, is engineered to nest at those specific step heights. A sleeve at 1100 mm height will not nest with a sleeve at 1100 mm from a different manufacturer because the rim tolerances differ. Joyrepak's standard step ladder guarantees nesting within the Joyrepak fleet.
Matching Footprint to Truck and Pallet Standards
The relationship between coaming box footprint and truck fleet standard is the key sizing decision in a returnable loop. Three reference standards cover most global truck fleets.
| Footprint | Truck Standard | Pallet Standard | Region |
|---|---|---|---|
| 1200x1000 mm | European standard truck / North American GMA truck | ISO 6780 / GMA pallet (1219x1016 mm) | Europe, North America, Middle East, Global default |
| 1150x985 mm | Asian-built truck / tight container width | ISO 6780-derived with tighter tolerance | Southeast Asia, China domestic, Japan, Korea |
| 1470x1150 mm | Wide-bed truck / oversize-load carrier | Custom pallet matching the wider footprint | Automotive assembly, large machinery, bulk food/agriculture |
Within the 1200x1000 family, Joyrepak offers the most extensive lid and divider options. Honeycomb box and divider sheets are stocked to match the 1200x1000 footprint, giving buyers in this family the broadest accessory catalog.
Why Standardization Matters Across Regions
Buyers who operate returnable loops across multiple regions face a footprint standardization decision. Standardizing on a single footprint (typically 1200x1000) simplifies the supplier relationship and the spare parts inventory, but forces trucks in tighter regions to run with dead space. Standardizing on regional footprints (1200x1000 in Europe, 1150x985 in Asia) optimizes each region but creates a dual inventory of lids, pallets, and sleeves.
Joyrepak supports both strategies from the same factory. The procurement team should decide which approach fits the operation before placing the first sleeve order.
Sizing Checklist for Specifying a Coaming Box
The following checklist runs through the sizing decisions in order. Going through it before requesting a quote prevents the most common cross-regional and cross-truck specification mistakes.
- Truck fleet standard. Identify the primary truck fleet (European / North American GMA / Asian-built / wide-bed oversize). This sets the footprint family.
- Pallet standard in use. Identify the pallet standard in use (ISO 6780 / GMA / custom). Confirm the chosen footprint nests with the pallet.
- Maximum load cube per sleeve. Calculate the load cube per sleeve trip. Set the sleeve height from the step ladder to enclose the maximum load.
- Maximum payload per sleeve. Verify the sleeve wall and lid specification support the maximum payload. Standard SKUs cover typical loads; heavy-duty variants exist for higher payload.
- Racking clearance. Measure the rack upright-to-upright clearance in the destination warehouse. The footprint plus operating clearance must fit.
- Forklift side-shift capability. Confirm the forklift has side-shift if the 1470x1150 footprint is in scope. Standard forklifts handle 1200x1000 and 1150x985 without special setup.
- Loop return ratio. Estimate the sleeve return ratio (sleeves out vs sleeves back per trip). This determines the inventory multiplier and the lid loss rate to budget.
- Custom footprint need. If the truck fleet and load conditions do not match the three standard footprints, engage the Joyrepak R&D design team for a custom footprint analysis.
Once the checklist is complete, submit the dimensions and load requirement to the Joyrepak team through the contact page. The team will confirm the right sleeve pack SKU, lid family, and pallet base combination, and will provide a sizing reference chart for repeat ordering.