National Highway Traffic Safety Administration (NHTSA)
Federal Motor Vehicle Safety Standard No. 302: Flammability of Interior Materials
FMVSS 302
Commercial Truck Sleeper Cab Mattress Sizing
Commercial truck mattress metrology: 42x80", 38x80", DOT flammability FMVSS 302, and heavy-duty coil construction.
42x80" DOT Commercial Standard
Direct answer summary
Commercial semi-truck sleeper berths (Freightliner Cascadia, Peterbilt 579, Kenworth T680, Volvo VNL) use specialized dimensions distinct from residential bedding. The most common commercial sleeper size is 42 x 80 inches (Freightliner / Volvo wide berth), followed by 38 x 80 inches and 36 x 80 inches. Crucially, commercial truck mattresses must comply with Federal Motor Vehicle Safety Standard FMVSS 302 for automotive interior flammability.
Key points
Freightliner and Volvo standard sleeper cabs utilize 42 x 80 inch mattresses.
Kenworth and Peterbilt models commonly use 38 x 80 or 36 x 80 inch bunk dimensions.
Must comply with Department of Transportation (DOT) flammability standard FMVSS 302.
Interactive example
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3D Layer-Peel Visualizer
Interactive Visual Tool
Interactive Exploded Architecture & Layer Inspection
Peel through the physical mattress assembly to audit coil gauge, foam density (PCF), indentation load deflection (ILD), and flame barrier composition.
What's insideDrawing only, layer order not confirmed
Commercial Sleeper Cab Bunk Profile layers
Height: 8.00"
Layers: 2 Layers
1/2
All
Active Layer: Heavy Quilted Cover
1" (QUILT)Thickness: 1"Material: FMVSS 302 Fabric
Layers, top to bottom (2)
Click to expand specsDOT flammability compliant cover
Thickness1 inches12.5% of stack
MaterialFMVSS 302 Fabric
Heavy-duty road vibration dampening coils
Thickness7 inches87.5% of stack
MaterialCommercial Pocket Coils
Coil Wire Gauge13.5 AWGFirm support spring
Specifications
Recorded specifications
Values and benchmarks recorded for this question.
| Specification | Measured value | Benchmark | Status |
|---|---|---|---|
| Standard Wide Berth Size | 42.0" W x 80.0" L (Freightliner / Volvo) | Commercial Truck Standard | pass |
| Standard Slim Berth Size | 38.0" W x 80.0" L (Peterbilt / Kenworth) | Mid-Roof Sleeper Size | pass |
| DOT Flammability Standard | FMVSS 302 Certified Burn Rate (<4"/min) | Mandatory DOT Road Standard | pass |
| Vibration Dampening | Heavy-Duty Pocket Coils + 2.0 PCF Foam | Isolates Diesel Engine Rumbles | pass |
Standards reference: Benchmarks derived from ASTM D3574 (flexible cellular foam), CPSC 16 CFR 1633 (open flame flammability), and clinical capillary closing thresholds (32.0 mmHg).
Checklist
Foundation Rigidity & Slat Support Audit
Step-by-step checklist to verify bed frame compliance, slat spacing tolerances, and center support.
- 01
Measure Cab Bunk Pan
Measure the steel bunk pan width and length inside your sleeper cab before ordering.
Watch for: Do not squeeze a 42-inch mattress into a 38-inch Peterbilt bunk pan.
- 02
Verify FMVSS 302 Compliance
Ensure the replacement mattress law tag explicitly certifies FMVSS 302 compliance.
Watch for: Using non-DOT residential mattresses in commercial cabs can violate DOT safety audits.
- 03
Opt for 8" to 10" Profile
Select a profile that leaves adequate head space beneath upper fold-down bunks.
Watch for: Avoid ultra-thick 14" mattresses that eliminate overhead bunk headroom.
Sources
Sources for this answer
Read the source documents behind the thresholds, measurements, and policy details used here.
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FMCSA
Federal Motor Carrier Safety Administration Commercial Sleeper Regulations
49 CFR § 393.76