Gaylord box size reference.
Standard footprints, height options and weight capacities for every Gaylord we stock — plus the logic for choosing one and ordering custom when stock won't fit.
Spec a Gaylord for your load
Give us the weight, contents and destination and we'll match a stock size — or spec a custom bin — and send freight-included pricing.
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Standard Gaylord boxes measure 40 × 48 inches to sit squarely on a GMA pallet, with heights from 24 to 60 inches and wall construction from single-wall to 5-wall. Capacities run from about 500 pounds for a half-height single-wall bin up to 2,500 pounds for a 5-wall export box. Choose by load weight first, then height and footprint.
Full Gaylord size chart
| Name | Dimensions (L × W × H) | Wall | Capacity | Typical use |
|---|---|---|---|---|
| Standard 40×48×36 | 40" × 48" × 36" | Double | ~1,200 lb | General bulk storage, WIP |
| Standard 40×48×48 | 40" × 48" × 48" | Double / Triple | ~1,500 lb | High-volume light goods |
| Heavy 40×48×36 | 40" × 48" × 36" | Triple | ~2,000 lb | Dense parts, castings, glass |
| Octagon / bin | 48" × 40" × 40" | 4-wall | ~2,000 lb | Free-flowing granules, produce |
| Half-height 40×48×24 | 40" × 48" × 24" | Single / Double | ~600 lb | Ergonomic picking, light bulk |
| Export 41×41×45 | 41" × 41" × 45" | 5-wall | ~2,500 lb | International, heavy machinery |
| Tall 40×48×60 | 40" × 48" × 60" | Triple | ~1,400 lb | Textiles, foam, insulation |
| Compact 30×30×30 | 30" × 30" × 30" | Double | ~500 lb | Small-footprint bulk, e-waste |
The standard 40 × 48 footprint
The classic Gaylord shares its footprint with the North American GMA pallet: 48 inches long by 40 inches wide. That is not a coincidence. Matching the box to the pallet means the bin loads onto a rack, a forklift or a trailer without overhang (which crushes corners) or wasted deck (which loses cube). When people say "standard Gaylord," this is the footprint they mean — the height is what changes.
Height options
Heights typically run from 24 inches (half-height bins for ergonomic picking and light bulk) through 36 and 48 inches (the everyday workhorses) up to 60 inches for light, voluminous goods like textiles, foam and insulation. Height is driven by volume and by how the box is handled: a tall bin holds more but is harder to reach into and less stable when partially filled.
A useful rule of thumb: pick the shortest height that holds your volume. It keeps the load's center of gravity low, stacks more predictably, and is kinder to the people filling and emptying it.
How to choose a size by weight and contents
Sizing a Gaylord is a two-step decision. First, the wall count carries the weight: dense goods — castings, glass, metal parts — want triple-, 4- or 5-wall board, while light bulk is fine on single- or double-wall. Second, the height holds the volume: match it to how much product you need per bin without overfilling past the top edge, which weakens stacking.
Then sanity-check against your pallet and your racking. A bin that carries the weight but overhangs the pallet will fail in transit; one that fits the pallet but is too tall for your rack bay wastes the space above it. When the weight, volume, pallet and rack all agree, you have your size.
For a deeper look at wall construction, see corrugated wall types →
Weight capacity by wall count
Capacity is set by wall construction, not by footprint. As a working guide, expect roughly these limits for a static, evenly-loaded, single-stacked bin — always add a margin over your real load and step up a wall if boxes are stacked, stored long-term, or handled roughly.
| Wall | Typical capacity | Best for |
|---|---|---|
| Single-wall | ~300–600 lb | Light bulk, half-height picking bins, dividers |
| Double-wall | ~1,000–1,500 lb | Standard Gaylords, most bulk and WIP loads |
| Triple-wall | ~1,400–2,000 lb | Dense parts, glass, castings, tall bins |
| 4-wall | ~2,000–2,300 lb | Very heavy loads, machinery |
| 5-wall | ~2,500 lb+ | Extreme-duty and long-haul export |
Figures are general guidance for planning, not certified ratings. Where documented ECT or Mullen numbers are required — food-grade, export or spec-critical loads — we supply certified new stock.
Loading & stacking tips
- Fill from the middle out. Keep the load centered so weight sits over the pallet stringers, not the unsupported deck between them.
- Don't overfill. Product mounded above the top edge stops the walls from carrying stack load and invites crush.
- Strongest on the bottom. When stacking bins, put the highest wall count and best grade underneath.
- Cap for stacking. A lid spreads the load of the bin above and keeps corners square through multiple cycles.
- Band or wrap tall bins. 60-inch and export bins benefit from strapping or stretch-wrap to hold geometry in transit.
- Ship empties flat-folded. Knocked-down bins cube out far denser, cutting freight cost and carbon on the return leg.
Custom sizing
When no stock size fits — an unusual pallet, an odd product profile, an export footprint — we spec custom Gaylords to your load. That includes non-standard dimensions, tailored wall counts, and specialty liners such as food-grade, foil or poly for moisture and contact requirements.
Send the weight, contents, quantity and destination, and we will come back with a made-to-fit recommendation and firm, freight-included pricing.
Ready to shipWrapped and banded bins hold their geometry through transit and multiple reuse cycles.Height & wall selection, together
Height and wall are chosen as a pair. A tall bin holds more volume but concentrates more weight on the bottom flutes and raises the load's center of gravity — so as height goes up, wall count often needs to as well. A 60-inch bin of light foam can stay double-wall; the same bin filled with dense parts wants triple- or 4-wall.
The safest reading of the pair: pick the shortest height that holds your volume, then pick the wall that carries the weight at that height with a margin. Short-and-strong beats tall-and-marginal almost every time.
Compare all wall types →Browse used and new Gaylords, or send us your specs for a matched quote.
Frequently asked questions
What is the standard Gaylord box size?
The standard Gaylord footprint is 40 by 48 inches to match a GMA pallet, most commonly with a height of 36 or 48 inches. Wall construction (double, triple and up) varies with the load, and capacities range from roughly 500 to 2,500 pounds.
How much weight can a Gaylord box hold?
It depends on wall count. A double-wall Gaylord typically carries around 1,000–1,500 lb, triple-wall 1,400–2,000 lb, and 4- or 5-wall export bins 2,000–2,500 lb or more. Always match the wall to your actual load weight plus a safety margin.
How do I choose the right Gaylord size?
Start with the load: its weight, density and volume. Pick a wall construction that carries the weight, a height that holds the volume without overfilling, and a footprint that matches your pallet. Dense goods want more walls and less height; light, bulky goods want the reverse.
Can I order custom Gaylord sizes?
Yes. When stock sizes do not fit, we spec custom dimensions, wall counts and liners to your load and pallet. Send the weight, contents and destination and we will quote a made-to-fit bin, freight included.
What is the difference between inside and outside dimensions?
Inside dimensions (ID) are the usable space your product sits in; outside dimensions (OD) are the box footprint for racking, pallet fit and truck cube. On triple- and multi-wall board the two can differ by an inch or more per side, so tell us which set matters: ID for product fit, OD for storage and freight.
How many Gaylords fit on a truck?
A 53-foot dry van holds roughly 26–30 standard 40×48 Gaylords on the floor, or more when bins are stackable and stable. Half-height and knocked-down (flat-folded) bins ship far denser, which is why empties are usually freighted flat-folded to save cube.
Are Gaylord boxes stackable when full?
Yes, within limits set by wall count, grade and how square the corners still are. Double-wall bins typically stack two to three high, triple- and multi-wall higher. Keep the load centered, avoid overfilling past the top edge, and put the strongest boxes on the bottom of the stack.
Do Gaylord boxes come with lids or pallets?
Both are optional add-ons. We can supply matching lids (telescoping or flat caps) for stacking and dust control, and GMA or export-rated (ISPM-15) pallets to ship on. Specify them with your order and we will price them into the quote.