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How to Size a Cargo Lift: Capacity, Platform Size, Travel Height and Door Configuration
Four measurements decide whether a cargo lift fits your building and your loads. Get them right before you request a quote, and you avoid the two expensive mistakes: a lift that is too small, or a lift that does not fit the space.
How do you size a cargo lift? The short answer
Size a cargo lift by working through four numbers in this order: rated capacity, platform size, travel height, and door configuration. Capacity must cover your heaviest load plus the pallet truck or cart that carries it. The platform must be larger than the load. Travel height is the floor-to-floor distance. The door layout must match how goods actually enter and leave.
- 1. Capacity(Heaviest load + handling equipment) × 1.2. Pick the next rated size up.
- 2. PlatformLargest load footprint + about 100 mm clear on every side.
- 3. Travel heightFinished floor to finished floor, then check headroom for the mast.
- 4. DoorsDecide which sides the load enters and exits, and leave room for the gate to swing.
A guide rail cargo lift is a self-supporting steel tower with a platform. It bolts onto a reinforced floor, so it can go into a building that was never designed for vertical transport. That freedom is also why sizing matters: nothing in the building forces the dimensions for you. This guide shows how Risenmega engineers work through each of the four decisions, with the real specifications of our three standard cargo lift types.
Not sure a cargo lift is the right category at all? Read our comparison of a cargo lift vs. a freight elevator first, then come back here to size it.
1. Cargo lift capacity: size for the load plus the equipment
Rated capacity is the maximum total weight the platform may carry at one time. The number most buyers quote is the weight of the goods only. The platform, however, also carries whatever moves those goods onto it.
Worked example. Your heaviest pallet weighs 650 kg and you move it with a manual pallet jack of about 90 kg (read the weight on your own jack's nameplate).
650 kg + 90 kg = 740 kg → 740 kg × 1.2 = 888 kg → choose a 1,000 kg lift. A 400 kg wire rope lift would be overloaded, even though "650 kg" sounds close to what the lift advertises.
Match the result to a Risenmega capacity class
| If your required capacity is… | Choose | Why |
|---|---|---|
| Up to 400 kg | Single Rail Wire Rope Cargo Lift | Lightest, most economical option, with the tallest reach (up to 15 m) in a compact footprint. |
| 400 to 1,000 kg, loads fit an 800 × 1000 mm platform | 1 Ton Single Rail Hydraulic Cargo Lift | More than double the wire rope capacity in the same compact platform. |
| Up to 1,000 kg with large or bulky loads, or 1 to 2 tons | 1-2 Ton Double Rail Hydraulic Cargo Lift | Dual guide rails keep a wide platform level even when the load sits off-centre. |
| Above 2 tons, up to 10 tons | Heavy Duty Electric Guide Rail Cargo Lift | Custom-engineered range from 0.2 to 10 tons, with platform size and capacity built to your cargo. |
2. Platform size: measure the largest load, then add clearance
Take the length and width of your largest single load, whether that is a pallet, a cage, a drum cradle, or a sofa. Add roughly 100 mm of clear space on every side so the load can be placed without scraping the guardrail. Then check that the pallet truck can turn or reverse out. Many standard pallets are 1,200 mm long, which immediately rules out some platform shapes.
| Load | Size (mm) | 800 × 1000 platform | 2000 × 1500 platform |
|---|---|---|---|
| ISO pallet | 1200 × 1000 | Does not fit | Fits, with the jack |
| EUR / EPAL pallet | 1200 × 800 | Does not fit | Fits, with the jack |
| GMA pallet (48 × 40 in) | 1219 × 1016 | Does not fit | Fits, with the jack |
| Half pallet | 800 × 600 | Fits | Fits several |
| Totes, cartons, hand trolley | up to 700 × 900 | Fits | Fits several |
| Sofa, fridge, large cabinet | varies | Usually not | Fits |
Platform size is also an opening-size decision
The platform has to pass through the upper floor, so the opening must be at least as large as the platform plus working clearance. Compare overall footprints before you commit: the Single Rail models occupy about 1000 × 1000 mm, and the Double Rail model about 2500 × 1500 mm. If a bigger platform means cutting a bigger hole in the mezzanine, that cost belongs in the same decision.
3. Travel height: measure floor to floor, then check headroom
Travel height is the vertical distance the platform must move: from the finished floor at the lowest stop to the finished floor at the highest stop. Measure to the finished surface, including any screed, tiles or raised flooring, and not to the structural slab. If the lift serves more than two levels, give us the height of each floor and the number of stops.
How much taller than travel height is the mast?
The mast is always taller than the travel height, because the guide rail extends above the highest stop. From our specification tables, overall height is roughly travel height plus 1.4 m for the wire rope lift, plus 1.0 m for the single rail hydraulic lift, and plus 2.0 m for the double rail lift. Check that this fits under your ceiling or roof, or plan for the mast to project above it.
| Model | Travel height | Overall height ≈ | Motor power | Voltage |
|---|---|---|---|---|
| Single Rail Wire Rope (400 kg) | 2 to 15 m | travel + 1.4 m | 1.6 kW (2 to 6 m), 3 kW (7 to 15 m) | 220 / 110 / 380 V |
| Single Rail Hydraulic (1,000 kg) | 2 to 12 m | travel + 1.0 m | 2.2 kW (2 to 7 m), 3 kW (8 to 12 m) | 220 / 110 / 380 V |
| Double Rail Hydraulic (1 to 2 t) | 2 to 12 m standard, custom up to 15 m | travel + 2.0 m | 3 kW | 220 / 110 / 380 V |
| Heavy Duty Electric Guide Rail | 3 to 15 m, taller on request | Per drawing | Per capacity | Customised |
Which drive suits your height? Wire rope reaches the highest stops at a lower power draw, while hydraulic gives a smoother ride and more capacity in the same footprint. Our guide to choosing the perfect cargo lift for your business compares them in detail.
4. Door configuration: plan how the load gets on and off
Door configuration means which sides of the platform are used for loading, and how each side is closed when the lift is moving. It is the sizing decision buyers most often leave until installation day, and it is the one that is hardest to change afterwards. Three layouts cover almost every project.
A. Same side in and out
Goods enter and leave through the same face. It is the simplest and cheapest layout, and it suits a mezzanine where the lift sits against a wall or in a corner. The operator must reverse the load out, so the platform needs room for the pallet truck to manoeuvre.
B. Straight through
Loads enter on one side and exit on the opposite side without turning. It keeps one-way traffic flowing in high-throughput warehouses and avoids reversing a pallet truck onto the platform. It needs floor space on both sides of the lift at every stop.
C. 90° corner
The load enters one face and leaves through the adjacent face. It is the answer when the upper floor layout forces a turn, but it takes the most planning because the turning space must exist on both levels.
Gates, guarding and controls
- Swing gate clearance. A swing gate needs floor space about equal to its width to open. In tight aisles, give us the available space so we can plan the gate direction.
- Guarding at each stop. Risenmega platforms are enclosed by a safety railing and swing gate. At the upper floor, tell us about the open edge around the floor opening so landing guarding can be included in the design.
- Where you operate it. Control can be multi-floor push buttons, or an industrial wireless remote on the Double Rail model. Operators should be able to see the platform and every gate from where they stand.
- Built-in protection. Overload protection stops the lift from running above its rated capacity, and hydraulic models include a manual release valve to lower the platform to ground level during a power cut.
Site checks before you order
- Base. Risenmega guide rail cargo lifts install on a solid concrete floor or with a very shallow ramp, with no deep pit. Confirm the slab can carry the lift's weight plus its rated load.
- Power. Choose 220 V, 110 V or 380 V to match your site. Tell us your plug or supply standard when you request the quote.
- Floor opening. Plan the upper-floor opening (platform plus clearance) and confirm the structure around it can be modified.
- Delivery path. Check that the packed components can reach the installation area. Risenmega machines ship from Qingdao Port with FOB, CIF or DDP options and documentation provided before shipment.
Send us your measurements and we reply with a reference drawing like this for your project.Put it together: which Risenmega cargo lift fits your numbers?
Once you have your capacity, platform, height and door layout, the model usually selects itself.
400 kg Single Rail Wire Rope
High reach for lighter loads: totes, cartons and files in tight spaces.
- Capacity
- 400 kg
- Platform
- 800 × 1000 mm
- Travel
- 2 to 15 m
- Footprint
- 1000 × 1000 mm
From $780
View this model
1 Ton Single Rail Hydraulic
Heavy loads and a smooth ride in a compact footprint, for dense goods in confined areas.
- Capacity
- 1,000 kg
- Platform
- 800 × 1000 mm
- Travel
- 2 to 12 m
- Footprint
- 1000 × 1000 mm
From $1,030
View this model
1-2 Ton Double Rail Hydraulic
Full pallets, furniture and appliances on a wide, stable, H-beam platform.
- Capacity
- 1 to 2 tons
- Platform
- 2000 × 1500 mm
- Travel
- 2 to 12 m (custom to 15 m)
- Footprint
- 2500 × 1500 mm
From $2,320
View this modelPrices are the "from" prices on our product pages at the time of writing and change with travel height and customisation. Need more than 2 tons or a custom platform? See the Heavy Duty Electric Guide Rail Cargo Lift (0.2 to 10 tons).
Six sizing mistakes that cost buyers money
Counting only the cargo
Forgetting the weight of the pallet jack, trolley or cage pushes the real load over the rating.
Platform equals pallet size
A 1200 mm pallet on a 1000 mm platform does not fit. Zero clearance also makes loading slow.
Mixing up travel and overall height
The mast is taller than the distance travelled. Check it against the ceiling before ordering.
Ignoring the upper floor opening
The platform needs a hole to pass through. Plan its size and edge protection early.
Forgetting the gate swing
A gate that opens into a pallet rack or a walkway is a daily nuisance and a safety risk.
Sizing for today only
If volumes or pallet sizes may grow, choose the next platform or capacity up now. Retrofits cost more than the difference.
Your sizing worksheet: what to send us
Send these eight items and our engineers can recommend a model, confirm the dimensions and reply with a quote and reference drawing. Partial information is fine; we will help you fill in the gaps.
- Heaviest load (kg) and what carries it
- Largest load size (length × width × height)
- Floor-to-floor height for every stop
- Number of stops and ceiling height at the top
- Loading sides at each stop (A, B or C layout)
- Power supply: 220 V, 110 V or 380 V, and plug type
- Controls: push buttons or wireless remote
- Photos or a sketch of the installation area
Cargo lift sizing: frequently asked questions
How much capacity does a cargo lift need?
Add the weight of your heaviest load to the weight of the pallet truck or cart used to move it, then multiply by about 1.2 for a safety margin. Choose the next rated capacity above that number. Risenmega standard lifts are rated at 400 kg (wire rope) and 1,000 kg (single and double rail hydraulic), with 1 to 2 ton and 0.2 to 10 ton options for heavier loads.
What platform size do I need for a standard pallet?
A standard 1200 × 1000 mm pallet needs a platform larger than both dimensions, plus space for the pallet jack. The 800 × 1000 mm platform on Risenmega's single rail lifts is too small for it. The 2000 × 1500 mm platform on the Double Rail model fits a full pallet with the jack, and custom sizes are available.
How high can a cargo lift go?
Risenmega's Single Rail Wire Rope lift reaches 15 m, the Single Rail Hydraulic lift 12 m, and the Double Rail Hydraulic lift 12 m as standard with taller builds on request. The Heavy Duty Electric Guide Rail lift is available from 3 to 15 m. Remember that the mast is taller than the travel height, so check your ceiling or roof clearance.
Does a cargo lift need a pit or an elevator shaft?
No. Risenmega guide rail cargo lifts are self-supporting and install on a solid concrete floor or with a very shallow ramp. You do need an opening in the upper floor for the platform to pass through, and a base that can carry the load.
Can people ride on a cargo lift?
A cargo lift is designed for goods. Do not carry people on it unless the specific model has been designed and certified for that use. Ask our engineers if your application involves personnel.
What information do I need to get a cargo lift quote?
Send your heaviest load, largest load size, floor-to-floor height at each stop, loading sides, power supply, and a photo or sketch of the installation area. Our engineers will recommend a model, confirm dimensions and prepare a quote.
Not sure about your numbers? We'll size it with you.
Send your floor heights, load weight and a photo of the space. A Risenmega engineer will recommend the right cargo lift, confirm the platform and door layout, and quote with CE documentation, container consolidation and worldwide shipping from Qingdao.
