Aluminum vs. Steel: Which is the Best Van Shelving & Storage Choice?
30th Aug 2022
The shelving you choose impacts how organized your van is, how much you can carry, and how much you spend on fuel and maintenance. Steel and aluminum are the most common materials, each with strengths that affect your payload, durability, and overall cost of operation.
While steel has long been the trusted material for strength and durability, aluminum shelving is rapidly gaining ground as a lighter, efficient alternative that helps you carry more, save on fuel, and extend your van’s life.
Choosing between steel and aluminum depends on your trade, workflow, and daily needs. This guide breaks down the key differences so you can decide which shelving system fits your van and business best.
Aluminum Van Shelving: Built for Trades
Aluminum shelving has gained popularity for delivering the strength needed on the job without unnecessary weight. Modern aluminum alloys are durable, naturally corrosion-resistant, and ideal for vehicles that need to carry more cargo or improve fuel efficiency.
Packd takes these advantages further. This premium modular aluminum shelving system is purpose-built for trade professionals who want to work smarter – with lighter builds, longer-lasting durability, and configurations tailored to your van, trade, and workflow. Every shelf is engineered for the demands of daily use, while keeping weight low enough to save fuel and preserve payload capacity.
Why choose Packd Aluminum Shelving:
- Significantly lighter than steel — ideal for maximizing payload and efficiency.
- High strength-to-weight ratio — each shelf supports 250 lbs.
- Naturally corrosion-resistant — no special coatings required.
- Improves fuel economy — reducing vehicle upfit weight saves fuel and can extend EV range.
- Protects payload capacity — typically uses just 5–8% of a van’s payload, keeping over 90% free for tools, parts, and cargo.
Who is Packd for:
- Trades that need maximum payload without sacrificing strength.
- EV upfits where weight impacts range and battery life.
- Applications that require corrosion resistance, such as food transport, cold storage, and lab environments.
Steel Van Shelving: Advantages & Trade Offs
Steel has been a mainstay in the trades for decades. It’s an alloy of iron and carbon, valued for its strength and density, making it capable of handling the heaviest loads. Many steel systems are coated for corrosion resistance and can be cost-effective upfront.
Steel shelving advantages:
- High load capacity — strong and stable for heavy tools and equipment.
- Durable construction — resists bending or warping under pressure.
- Lower initial cost — can be more affordable upfront depending on grade and design.
Where steel excels:
- Storing heavy auto parts or machinery.
- Trades that transport extra-long or heavy items such as in plumbing, HVAC, or contracting.
- Driving in rough conditions where rigidity is important.
The trade-off:
Steel’s weight is significant. A typical package can weigh 450–700 lbs, consuming up to 20% of your van’s payload before you’ve loaded any tools or cargo. That weight also reduces fuel efficiency – every 100 lbs can lower fuel economy by roughly 1% (U.S. EPA).
Steel vs. Aluminum Van Shelving Weight at a Glance
| Brand | Warranty (yrs) | Weight (Base Package) | Payload Capacity Lost | Shelving Weight Rating |
|
Packd |
12 |
196lbs |
5% |
250lb per shelf tray |
|
American Van |
0 |
685lbs |
18% |
Not Published |
|
Weatherguard |
3 |
442lbs |
12% |
150lb per shelf tray |
|
Ranger Design |
10 |
267lbs |
7% |
250lb per shelf tray |
|
Adrian Steel |
3 |
439lbs |
12% |
125lb per shelf tray |
|
Holman |
3 |
422lbs |
11% |
150lb per shelf tray |
|
Masterack |
1 |
400lbs |
11% |
Not Published |
All specs are based on upfitting a Ford Transit 148” WB MR Van with a vehicle payload capacity of 3,800lbs. Base Package includes a Partition/Bulkhead and shelving units on both sides of the van
Choosing Between Steel and Aluminum Van Storage
If your work demands extreme load capacity for the heaviest equipment, steel may still be an option. But for most tradespeople, fleet operators, and business owners, aluminum shelving delivers clear advantages:
- Reduces fuel and operating costs.
- Preserves payload capacity for what actually makes you money.
- Minimizes wear on your vehicle’s suspension, brakes, and drivetrain.
Single Shelving Unit Weight Comparison:
Why Packd is the Smarter Aluminum Choice
Packd’s premium modular aluminum shelving systems are engineered for real work and real results:
- Industry-leading durability, backed by a 12-year manufacturer’s warranty.
- Modular configurations to fit your van type, trade, and workflow.
- Lighter than steel — ideal for maximizing payload and efficiency.
- High strength-to-weight ratio — each Packd shelf supports 250 lbs.
- Naturally corrosion-resistant — no special coatings required.
- Improves fuel economy — removing excess weight saves fuel and can extend EV range.
- Protects payload capacity — Packd systems typically use just 5–8% of a van’s payload, keeping over 90% available for tools, parts, and cargo.
- Made from recyclable aluminum — better for you, better for the planet.
Make the Switch to Packd
Free up payload, cut fuel costs, and carry more of what matters. Built tough for the job, engineered for the road.
FAQs: Steel vs Aluminum Van Storage & Shelving
How much lighter is aluminum than steel?
Steel shelving packages can add 450–700 lbs to your van. Packd aluminum shelving packages are usually under 200 lbs, leaving more payload for the tools and materials that make you money.
Will aluminum shelving hold up like steel?
Absolutely. Packd shelves are rated for 250 lbs each, resist rust and corrosion, and are built for the demands of daily work.
What is Packd and why should I choose it?
Packd is a company manufacturing premium aluminum van upfit products and shelving systems built for pros who want strength without the weight. It’s tough, modular, and backed by a 12-year warranty, so it works as hard as you do, for years to come.
Which vans work with Packd?
Packd is made for all the most popular work vans, including Ford Transit, Mercedes-Benz Sprinter, RAM ProMaster, GMC Savana, and Chevy Express. Each setup is designed for a perfect fit.
Are there packages for my trade?
Yes. Packd offers complete setups for electricians, HVAC techs, plumbers, and more — so you can get organized and get to work right away.
Need more help?
Find more how-to guides, product support and expert advice in our Resources or Contact Us with any questions.