Measure twice, order once

The Gaylord box size guide

Dimensions, wall grades and weight ratings — decoded. Use the charts and articles below to spec the right box before you spend a dollar.

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The short answer

A “Gaylord” is any pallet-sized bulk box, usually built on a 40″ × 48″ footprint to match a standard GMA pallet. The three things that define one are footprint (length × width), height (commonly 36″–48″), and wall grade (single, double or triple-wall), which sets how much it can safely hold. Get those three numbers right and the box does its job for one trip or twenty; get them wrong and you crush corners, waste cube, or over-pay for board you never needed.

Master reference

Common Gaylord dimensions

Fifteen of the most-requested sizes, with outside and inside measurements, usable cubic-foot volume and the pallet footprint each one matches. Odd sizes are our specialty — ask.

Outside (L × W × H, in)	Inside (approx, in)	Volume (cu ft)	Footprint match	Wall
30 × 30 × 30	29 × 29 × 29	14.1	Quarter / half-Gaylord	2-wall
30 × 30 × 34	29 × 29 × 33	16.0	Octabin footprint	3-wall
32 × 30 × 34	30½ × 28½ × 33	16.6	Half-pallet bin	2-wall
36 × 36 × 36	34½ × 34½ × 35	24.1	Square, small bulk	2-wall
40 × 48 × 30	38½ × 46½ × 29	30.0	GMA pallet, low bin	1-wall
40 × 48 × 36	38½ × 46½ × 35	38.6	GMA pallet, mid-height	2-wall
40 × 48 × 40	38½ × 46½ × 39	42.9	GMA pallet, general bulk	2-wall
40 × 48 × 45	38½ × 46½ × 44	48.4	GMA pallet, tall	2-wall
40 × 48 × 48	38 × 46 × 47	47.4	GMA pallet, max volume	3-wall
41 × 41 × 45	39½ × 39½ × 44	39.8	Square footprint	2-wall
42 × 42 × 42	40½ × 40½ × 41	38.9	Square, rotational pack	2-wall
44 × 36 × 42	42½ × 34½ × 41	34.8	Custom slotted bin	3-wall
47 × 39 × 39	45½ × 37½ × 38	37.5	Euro-style import	2-wall
48 × 40 × 42	46½ × 38½ × 41	42.4	GMA pallet, rotated	3-wall
48 × 40 × 48	46 × 38 × 47	47.6	GMA pallet, tall bulk	3-wall

Dimensions are nominal outside measurements; usable inside space is roughly ¾″–1½″ smaller per side depending on wall grade. Volume is interior cubic feet, calculated as (ID length × ID width × ID height) ÷ 1,728. For a full breakdown by footprint and height, see the dimensions guide.

Know the box

Anatomy of a Gaylord

Six parts do all the work. Understand them and every spec sheet reads like plain English.

Strip a Gaylord down and it is just three ingredients repeated: two flat liners with a wavy fluted medium glued between them. One flute layer is single-wall; stack two or three and you get the double- and triple-wall board that lets a bulk box carry a ton of dense product without buckling. The flutes stand vertically in the wall, which is why a box is far stronger top-to-bottom than side-to-side — and why stacking load rides on the walls, never on the product inside.

The corners are the strongest point of any corrugated box, carrying the majority of a stack's compression load. That is why overhang is so damaging: let the box hang even an inch past the pallet edge and those corners lose their support, dropping strength 20–30%. The base takes the product weight, the walls take the stack, and an optional lid or telescoping cap ties the top together and keeps out dust.

Liners

The flat inner and outer faces. Heavier liners lift both ECT and burst.

Flute

The fluted medium between liners. Its profile sets thickness and cushioning.

Walls & corners

Vertical flutes carry the stack; corners carry the most of all.

Base & lid

The base holds product weight; a cap protects the load and squares the top.

Convert it fast

Unit-conversion reference

Freight talks in inches and pounds; imports and spec sheets talk in centimeters and kilograms. Keep both tables handy so nothing gets lost in translation.

Length & height

Inches	Centimeters	Feet	Meters
30″	76.2 cm	2.50 ft	0.762 m
36″	91.4 cm	3.00 ft	0.914 m
40″	101.6 cm	3.33 ft	1.016 m
41″	104.1 cm	3.42 ft	1.041 m
45″	114.3 cm	3.75 ft	1.143 m
48″	121.9 cm	4.00 ft	1.219 m

Factor: 1″ = 2.54 cm. Multiply inches by 2.54 for centimeters.

Load weight

Pounds	Kilograms	Metric tons	Ounces
250 lb	113 kg	0.11 t	4,000 oz
500 lb	227 kg	0.23 t	8,000 oz
1,000 lb	454 kg	0.45 t	16,000 oz
1,500 lb	680 kg	0.68 t	24,000 oz
2,000 lb	907 kg	0.91 t	32,000 oz
2,500 lb	1,134 kg	1.13 t	40,000 oz

Factor: 1 lb = 0.4536 kg. Volume: 1 cu ft = 0.0283 m³ = 7.48 US gallons.

The 30-second spec

Load-to-wall decision matrix

Start with the honest, wet weight of what goes in the box. This table maps that number to a recommended wall grade, target ECT and a sensible condition grade.

Load weight (lb)	Recommended wall	Target ECT	Condition grade	Typical product
Up to 300	Single-wall	32 ECT	A–C	Light returns, kitting, one-way ship
300 – 600	Single / double-wall	44 ECT	A–B	General light bulk, textiles, foam
600 – 1,000	Double-wall	48 ECT	A–B	Standard bulk, plastics, e-scrap
1,000 – 1,500	Double-wall	51–61 ECT	A	Dense product, produce, powders
1,500 – 2,200	Triple-wall	67 ECT	A–B	Heavy castings, resin, metal parts
2,200 +	Triple-wall	82–90 ECT	A	Max load, machined & bulk metal

Loads assume evenly distributed, palletized static weight in dry storage. Stacking, humidity and long dwell times all cut the safe limit — see the wall-grades guide and weight-capacities guide for the full math.

Match the deck

Pallet-compatibility table

A Gaylord is only as stable as the pallet under it. Pair the footprint to the deck so the box sits flush on all four edges — no overhang, no wasted cube.

Pallet type	Deck size (in)	Best box footprint	Overhang	Region / use
GMA / grocery	48 × 40	40 × 48	Flush	North American standard
CHEP / block (pooled)	48 × 40	40 × 48	Flush	Rental / one-way freight
Euro EUR-1	47.2 × 31.5	47 × 31	Flush	European & import loads
Square drum pallet	42 × 42	42 × 42	Flush	Rotational & agriculture
Industrial 4-way	48 × 48	48 × 48	Flush	Drums, heavy castings
Half GMA	48 × 20	20 × 48	Flush	Split loads, tight aisles

The 48″ × 40″ GMA pallet carries the vast majority of North American freight; a 40″ × 48″ box sits perfectly square on it. Overhang of even 1″ can cut compression strength 20–30%.

Go deeper

Guides in this size library

Focused articles for the decisions that matter — plus the primers behind them.

Gaylord Dimensions

Every standard footprint and height, and how to measure yours.

Wall Grades Explained

Single vs. double vs. triple-wall — and what each can carry.

Weight Capacities

Static vs. dynamic loads, stacking and safety factors.

Grade Glossary (A–D)

What our used-box condition grades really mean.

What Are Gaylord Boxes?

The full primer, from history to handling.

Buying Guide

Turn these specs into the right purchase.

Rules of thumb

How to choose in 60 seconds

When you don't have time for the deep dive.

Match the pallet

Pick a footprint that matches your pallet — usually 40″ × 48″ — so the box does not overhang or waste space.

Height = volume ÷ footprint

Taller boxes hold more but stack less. For heavy, dense product, go shorter and stronger.

Weight sets the wall

Under 500 lb: single-wall. 500–1,500 lb: double-wall. Over 1,500 lb or reuse: triple-wall.

Reuse favors triple-wall

If you want multiple trips, triple-wall Grade A/B pays for itself fast.

Leave headroom for lids

If you cap or stack, subtract lid height and plan for the top load.

When in doubt, ask

Send us the product and load weight — speccing boxes is literally our day job.

Speak the language

Glossary of Gaylord terms

The vocabulary that shows up on every spec sheet, packing slip and Box Maker's Certificate.

Term	What it means
Gaylord	Any pallet-sized bulk corrugated box, usually built on a 40″ × 48″ footprint. Named after the Gaylord Container Company.
OD (outside dimension)	Wall-face to wall-face measurement. Sets pallet fit and how many boxes ride in a trailer.
ID (inside dimension)	Usable interior measurement — smaller than OD by the wall thickness on each side.
Footprint	The length × width of the base, matched to a pallet deck so nothing overhangs.
Flute	The wavy fluted medium glued between flat liners. Profiles run A, B, C, E and F, thickest to thinnest.
Liner	The flat facing sheets on each side of the flute. Two liners plus one flute equals single-wall.
ECT (edge crush test)	Vertical stacking strength in pounds per linear inch — the number that predicts compression failure.
Mullen burst	Puncture resistance in pounds per square inch — how the board handles impacts and sharp loads.
GMA pallet	The 48″ × 40″ Grocery Manufacturers Association pallet — the most common deck in North America.
Octabin	An eight-sided bulk bin, typically 30″-class, used for free-flowing powders, granules and resin.
Telescoping lid	A separate cap that slides over the top of the box for stacking and dust protection.
Condition grade (A–D)	Our used-box rating: A is near-new, D is recycle-only. It sets reuse count and strength.

Common questions

Size guide FAQ

What is the most common Gaylord box size?

The 40″ × 48″ × 36″ double-wall box is the workhorse. It matches a GMA pallet exactly, holds roughly 38 cubic feet of usable space, and stacks cleanly two or three high.

How do I know how strong a box I need?

Start with the wet weight of your product and read across the load-to-wall matrix above. Under 500 lb runs single-wall; 500–1,500 lb is double-wall territory; over 1,500 lb or any repeated reuse calls for triple-wall. When in doubt, size up one grade.

Why is the inside dimension smaller than the outside?

Wall thickness. A single-wall board runs about ⅛″; triple-wall stacks three fluted layers and can measure ⅝″ or more per wall — so inside dimensions drop 1″–1½″ per side versus outside. Always confirm whether a quoted number is OD or ID.

How many cubic feet does a Gaylord hold?

Multiply the three inside dimensions in inches and divide by 1,728. A 40″ × 48″ × 36″ box gives roughly 36–39 cu ft; a full 48″-tall box pushes toward 47–48 cu ft. The master table above lists usable volume for every size.

Can I order a size that isn't on the chart?

Yes — odd footprints are our specialty. Send the product, load weight and pallet to request a quote and we'll spec a custom box, then match it against our used and new inventory.

Do you sell both used and new Gaylords in these sizes?

Both. Graded used boxes cover most footprints above at a fraction of new-box cost, while fresh triple-wall is available when the load or reuse cycle demands it. Compare used and new inventory.

Right size, first time.

Tell us the load — we'll tell you the box.

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