For tradespeople, contractors, and fleet operators, a work van is more than just a vehicle; it is a mobile warehouse, an office, and a billboard. To maximize the efficiency of this workspace, utilizing the roof is essential. This is where the trusty ladder rack comes into play. It frees up valuable interior cargo space, prevents damage to the interior of your van, and allows you to transport oversized materials securely.
However, despite their utility, selecting and using a rack is not always straightforward. At Canadian Van Outfitters, we have seen the good, the bad, and the dangerous when it comes to roof storage setup. A poor choice or improper usage can lead to damaged equipment, vehicle wear and tear, and significant safety hazards.
To help you make the right investment and keep your fleet running smoothly, we have compiled a comprehensive guide on the most common mistakes professionals make regarding ladder racks and, more importantly, how to avoid them.
Mistake #1: Ignoring the Weight Capacity (Dynamic vs. Static)
One of the most dangerous errors a van owner can make is assuming a ladder rack can hold whatever you can physically fit onto it. Every rack system and every vehicle roof has a specific weight rating.
There is often confusion between static weight capacity (how much weight the rack can hold when the vehicle is parked) and dynamic weight capacity (how much it can safely hold while the vehicle is in motion). Dynamic capacity is almost always lower because the rack must withstand the forces of breaking, cornering, and acceleration.
How to Avoid It: Before purchasing, always check the owner’s manual of your vehicle to find the roof’s weight limit. Then, check the rating of the rack itself. You must adhere to the lower of these two numbers. Remember to account for the weight of the rack itself when calculating your total payload. If you frequently haul heavy conduit, lumber, and multiple extension ladders, you need a heavy-duty system designed for high dynamic loads.
Mistake #2: Choosing the Wrong Material for Your Climate
In the world of commercial van equipment, the debate usually comes down to steel versus aluminum. A common mistake is choosing steel simply because it is often cheaper upfront, without considering the long-term environmental impact.
In Canada, our roads are heavily salted during the winter. Steel, if the powder coating is scratched or chipped, is highly susceptible to rust. Over time, a rusting rack can stain your van’s paint and eventually lose structural integrity. Conversely, some choose aluminum but underestimate the heavy-duty nature of their work, potentially needing the rigidity of steel.
How to Avoid It: Analyze your environment. If you operate in areas with harsh winters and road salt, aluminum is generally the superior choice. It is naturally rust-resistant and lighter, which helps with fuel economy. If you are in a dry climate or need maximum rigidity for extreme heavy-duty hauling, steel might be acceptable, provided it has a high-quality galvanized or powder-coated finish.
Mistake #3: Overlooking Ergonomics and Worker Safety
Buying a static, fixed ladder rack for a high-roof van is a recipe for employee injury. If your technician has to climb a door-mounted ladder or balance precariously on a tire to untie a ladder from the roof several times a day, fatigue sets in. Fatigue leads to shortcuts, and shortcuts lead to accidents.
Many companies try to save money by buying a “basic” rack, only to pay for it later in Workers’ Compensation claims or damaged vehicles caused by dropped ladders.
How to Avoid It: Consider the height of your van and the physical stature of your team. For high-roof vans, a “drop-down” or “deployment” rack is an essential investment. These systems use hydraulic or spring-assisted mechanisms to bring the ladder down to the side of the van at a comfortable working height. It makes loading and unloading faster and significantly safer.
You can browse various ergonomic solutions in our extensive ladder rack catalog to find a system that protects your back and your bottom line.
Mistake #4: Improper Installation
We live in the age of DIY, and while we admire the spirit, installing a roof rack incorrectly is a major liability. Common installation mistakes include:
- Drilling holes into the roof without proper sealing (leading to leaks and rust).
- Overtightening bolts (stripping threads).
- Undertightening bolts (causing the rack to rattle loose).
- Placing the crossbars too far apart or too close together for the specific ladder length.
How to Avoid It: Always follow the manufacturer’s instructions to the letter. Use a torque wrench to ensure bolts are tightened to specification. If the rack requires drilling, ensure you are using distinct silicone sealants or weather-proofing washers provided with the kit. If you are unsure, professional installation is always worth the cost to ensure the rack stays on the van at highway speeds.
Mistake #5: Forgetting About Height Clearance
It is a sinking feeling: you install a new rack, load up your ladders, and drive into a parking garage—only to hear the sickening crunch of metal on concrete.
Adding a rack and ladders increases the vertical clearance of your vehicle significantly. Many drivers forget this new height, leading to collisions with drive-thru overhangs, parking garage beams, and even low-hanging tree branches.
How to Avoid It: Measure your vehicle’s total height after the rack and ladders are installed. Write this number down and place it on a sticker on the dashboard or the driver’s side sun visor. This constant visual reminder helps the driver make quick decisions about where they can and cannot fit.
Mistake #6: Ignoring Aerodynamics and Wind Noise
A square, blocky rack on top of a streamlined van creates drag. This results in two problems: increased fuel consumption and excessive wind noise. The “howling” sound of a poorly designed rack can be deafening at highway speeds, making it difficult for drivers to concentrate or take hands-free calls.
How to Avoid It: Look for racks that feature an airfoil or a wind deflector in the front. This simple piece of metal or plastic directs air over the top of the rack rather than through it. If you already have a rack that is noisy, aftermarket wind deflectors are available. Additionally, removing the rack or ladders when they are not needed for long periods can save on fuel.
Mistake #7: Relying on Bungee Cords for Securement
Perhaps the most common—and illegal—mistake is securing a heavy extension ladder with simple bungee cords. Bungee cords stretch, degrade in UV light, and can snap under tension. They are not rated to hold a ladder in place during a panic stop or a collision.
How to Avoid It: Use proper ratchet straps or, better yet, choose a ladder rack with integrated cargo stops and locking mechanisms. Many modern racks come with “ladder stops” that adjust to the width of your ladder and locking handles that clamp the ladder down firmly. This ensures the load becomes one with the vehicle.
Conclusion: An Investment in Efficiency
A ladder rack is not just an accessory; it is a critical component of your daily workflow. By avoiding these common mistakes—ranging from material choice to securement methods—you protect your vehicle, your equipment, and the people sharing the road with you.
At Canadian Van Outfitters, we understand the unique challenges faced by Canadian tradespeople. We are dedicated to providing equipment that stands up to the job, the weather, and the weight.
If you are unsure which system is right for your fleet or have questions about installation and capacity, we are here to help. Contact our team today for expert advice and personalized recommendations.
Frequently Asked Questions (FAQ)
Can I install a ladder rack on a van with a fiberglass roof? A: Yes, but you must be careful. You generally cannot clamp onto rain gutters on a fiberglass roof in the same way you do with steel. You will likely need a rack specifically designed to mount to the factory mounting points or tracks provided by the vehicle manufacturer to distribute the weight to the vehicle’s frame rather than the fiberglass shell.
How much weight can the average ladder rack hold? A: This varies significantly. A standard utility rack might hold 250 to 500 lbs, while heavy-duty cargo racks can handle 750 lbs or more. However, you are always limited by the roof weight rating of the van itself. Always check your vehicle owner’s manual.
What is the benefit of a drop-down (lock-down) rack? A: A drop-down rack lowers the ladder to the side of the van, usually at chest height. This eliminates the need to climb on tires or bumpers to reach the roof. It significantly reduces the risk of back injuries and falls, making it ideal for high-roof vans like the Ford Transit or Mercedes Sprinter.
Do ladder racks affect gas mileage? A: Yes, adding anything to the roof of a vehicle increases wind resistance (drag), which can lower fuel efficiency. However, choosing an aerodynamic rack made of aluminum and utilizing wind deflectors can minimize this impact.
How often should I inspect my ladder rack? A: We recommend a quick visual inspection every time you load a ladder. A more thorough inspection (checking for loose bolts, rust, or fatigue cracks) should be done once a month, or more frequently if you drive on rough, unpaved roads.