Flat-Pack vs Assembled Bunk Beds
Flat-pack vs assembled bunk beds: the freight trade-off
A knock-down (KD) flat-pack metal bed ships at roughly one-fifth to one-tenth the volume of an assembled bed, which cuts ocean freight sharply. For overseas buyers, KD is almost always cheaper despite on-site assembly labour. This guide quantifies the trade-off with a worked example.
Volume and freight math
| Format | Carton volume per bed | Sets per 40HQ |
|---|---|---|
| KD flat-pack (Zehao) | 0.10-0.13 CBM | 55-70 |
| Assembled | 0.60-1.20 CBM | 8-15 |
At an illustrative ocean rate, moving 60 KD beds may cost close to the freight of 10-15 assembled beds. For a 500-bed dorm, KD can save thousands of dollars in freight alone.
Assembly time
A two-person team assembles a KD metal bunk in about 15-25 minutes with supplied tools. For large projects we provide an assembly guide and can quote pre-assembled units on request.
When assembled makes sense
- Small orders where freight savings do not offset labour.
- Buyers without assembly capability on site.
- Retail shelf-ready stock.
Frequently asked questions
Is flat-pack weaker than assembled?
No. Zehao KD frames are welded at the factory and only bolted together on site, so structural strength is unchanged; SGS tests confirm 200 kg per berth.
How many beds fit in a 40HQ?
Roughly 55-70 KD bunk-bed cartons per 40ft high-cube container, depending on carton size.
Do you ship assembled on request?
Yes, pre-assembled units are available for smaller orders or buyers without assembly labour.
Related pages
Last updated: 2026-09-28. Freight figures are typical estimates; request a model-specific loading plan before booking.