Gaylord box dimensions, decoded
Every standard footprint and height in one chart — inside vs. outside measurements, cubic-foot volume, and exactly how to measure a box before you buy.
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A standard Gaylord is built on a 40″ × 48″ footprint to sit square on a GMA pallet, with heights from 36″ to 48″. Smaller “half-Gaylords” and octabins run about 30″ × 30″. The two numbers that matter are the outside dimension (OD) — what fits on the pallet and in the trailer — and the inside dimension (ID) — the usable space for your product. Wall grade eats roughly ¾″–1½″ per side, so always confirm whether a quoted figure is OD or ID before you order.
Standard 40″ × 48″ dimensions & volume
The GMA-footprint workhorses. Outside dimensions are nominal; inside and volume figures assume double- or triple-wall construction. Volume is usable interior cubic feet.
| Outside (L × W × H, in) | Inside (approx, in) | Volume (cu ft) | Typical use | Wall |
|---|---|---|---|---|
| 40 × 48 × 30 | 38½ × 46½ × 29 | 30.0 | Low bin, dense product | 1-wall |
| 40 × 48 × 36 | 38½ × 46½ × 35 | 38.6 | GMA pallet, mid-height | 2-wall |
| 40 × 48 × 40 | 38½ × 46½ × 39 | 42.9 | General bulk, retail returns | 2-wall |
| 40 × 48 × 45 | 38½ × 46½ × 44 | 48.4 | Foam, textiles, e-scrap | 2-wall |
| 40 × 48 × 48 | 38 × 46 × 47 | 47.4 | Tall bulk, low-density product | 3-wall |
Rule of thumb: cubic feet = (ID length × ID width × ID height) ÷ 1,728. Nominal capacity in the charts rounds to the box's rated fill line.
Half, octabin, square & custom sizes
When a full 40″ × 48″ box is too big, too tall or the wrong shape, these footprints do the job. Same OD-vs-ID convention throughout.
Half-Gaylords & octabins (30″ class)
| Outside (L × W × H, in) | Inside (approx, in) | Volume (cu ft) | Typical use | Wall |
|---|---|---|---|---|
| 24 × 20 × 23 | 23 × 19 × 22 | 5.6 | Quarter-pallet mini bin | 2-wall |
| 30 × 30 × 30 | 29 × 29 × 29 | 14.1 | Half-Gaylord, small parts | 2-wall |
| 30 × 30 × 34 | 29 × 29 × 33 | 16.0 | Octabin, powders & granules | 3-wall |
| 32 × 30 × 34 | 30½ × 28½ × 33 | 16.6 | Half-pallet bin | 2-wall |
Square footprints
| Outside (L × W × H, in) | Inside (approx, in) | Volume (cu ft) | Typical use | Wall |
|---|---|---|---|---|
| 36 × 36 × 36 | 34½ × 34½ × 35 | 24.1 | Compact square bulk | 2-wall |
| 41 × 41 × 45 | 39½ × 39½ × 44 | 39.8 | Agriculture, rotational | 2-wall |
| 42 × 42 × 42 | 40½ × 40½ × 41 | 38.9 | Rotational packing | 2-wall |
| 45 × 45 × 45 | 43½ × 43½ × 44 | 48.2 | Large square bulk | 3-wall |
Custom & rotated footprints
| Outside (L × W × H, in) | Inside (approx, in) | Volume (cu ft) | Typical use | Wall |
|---|---|---|---|---|
| 44 × 36 × 42 | 42½ × 34½ × 41 | 34.8 | OEM & automotive lines | 3-wall |
| 47 × 39 × 39 | 45½ × 37½ × 38 | 37.5 | Euro-style import | 2-wall |
| 48 × 40 × 42 | 46½ × 38½ × 41 | 42.4 | Resin, produce, castings | 3-wall |
| 48 × 40 × 48 | 46 × 38 × 47 | 47.6 | Tall, rotated GMA footprint | 3-wall |
Don't see your size? Odd footprints are our specialty — request a quote with your product and pallet.
How to measure a Gaylord
The difference between a box that fits and a box that fights you is one convention: always state whether a number is inside or outside.
Measure outside dimensions (OD) first
Length, then width, then height, wall face to wall face. OD determines pallet fit and how many boxes ride in a 53′ trailer. Standard OD is 40″ × 48″.
Measure inside dimensions (ID) for product fit
Drop a tape to the inside faces at the base. On triple-wall boxes ID can run 1½″ smaller per side than OD — that's 3″ off both length and width.
Set height to the fill line, not the flap
Interior wall height is your working volume. If you cap with a lid or telescoping top, subtract lid depth and leave headroom.
Account for the lid or cap separately
A telescoping lid adds 2″–4″ of overlap down the outside walls and 1″–2″ over the top. Measure the box body and the cap independently so your stack height is honest.
Match it to your pallet
A 48″ × 40″ GMA pallet wants a 40″ × 48″ box so nothing overhangs. Overhang crushes corners in transit and voids most stacking ratings.
Cubic capacity, worked out
Volume is simple arithmetic once you have the inside dimensions. Here are three worked examples straight from the charts above.
The formula never changes: cubic feet = (ID L × ID W × ID H) ÷ 1,728, because there are 1,728 cubic inches in a cubic foot (12 × 12 × 12). Multiply the three inside measurements in inches, then divide.
Example 1 — Half-Gaylord, 30″ × 30″ × 30″. Inside runs about 29 × 29 × 29 in. That's 29 × 29 × 29 = 24,389 cu in ÷ 1,728 ≈ 14.1 cu ft of usable space.
Example 2 — Square bin, 41″ × 41″ × 45″. Inside about 39½ × 39½ × 44 in. That's 39.5 × 39.5 × 44 = 68,651 cu in ÷ 1,728 ≈ 39.8 cu ft.
Example 3 — Tall bulk, 40″ × 48″ × 48″. Inside about 38 × 46 × 47 in. That's 38 × 46 × 47 = 82,156 cu in ÷ 1,728 ≈ 47.5 cu ft.
To turn volume into load weight, multiply usable cubic feet by your product's bulk density. Plastic regrind at roughly 25 lb/cu ft in that 47.5 cu ft box is about 1,188 lb — enough to demand triple-wall board. Sand at 100 lb/cu ft would blow past any Gaylord's rating long before the box filled, which is exactly why dense product goes in a shorter, stronger box.
How many fit in a 53′ trailer?
Floor positions assume standard 48″ × 40″ pallet slots in a 53′ dry van (roughly 630″ long × 98″ wide). Stacked counts assume boxes short enough to ride two high under a 108″ ceiling. Container figures are for a 40′ high-cube.
| Box size (OD) | Floor, 53′ van | Stacked, 53′ van | 40′ HC container | Notes |
|---|---|---|---|---|
| 40 × 48 × 36 | 26 | 52 | 20 | Standard; stacks two high in a van |
| 40 × 48 × 48 | 26 | 26 | 20 | Too tall to double-stack in a 53′ van |
| 41 × 41 × 45 | 28 | 28 | 22 | Square footprint packs tighter across |
| 42 × 42 × 42 | 26 | 52 | 21 | Rotational bins, two high |
| 48 × 40 × 42 | 26 | 52 | 20 | Rotated GMA footprint |
| 30 × 30 × 34 | 60 | 120 | 48 | Half-Gaylord / octabin, two high |
Counts are approximate and assume assembled boxes. Knocked-down (flat) Gaylords ship many times more per trailer — often 300–500 flats — which is why we recommend flat returns for empty inventory.
Overhang & pallet matching
Most freight in North America moves on the 48″ × 40″ GMA pallet — and every inch of overhang costs you strength.
A box described as “40 × 48” means 40″ on the pallet's 48″ face and 48″ on the 40″ face — flush on all four edges. The 41″ × 41″ square footprint suits product you rotate or pack from multiple sides. The 30″ × 30″ half-Gaylord and eight-sided octabin quarter the footprint for dense powders, resins and granules where a full 40″ × 48″ box would exceed safe load weight before it filled up.
Whatever the footprint, keep the box within the pallet edge. The corners are the strongest part of any corrugated box; let them hang unsupported and compression strength collapses. The table shows how fast it falls off.
| Overhang | Strength kept | Verdict |
|---|---|---|
| 0″ (flush) | 100% | Ideal — corners fully supported |
| ½″ per side | ≈ 90% | Acceptable for light loads |
| 1″ per side | ≈ 70–80% | Marginal — expect corner wear |
| 2″ per side | ≈ 55–65% | Avoid — crushing in transit |
| Corner off deck | ≈ 40% | Fails early; voids stacking rating |
Headroom for lids & stacking
When you stack loaded Gaylords, the top box rides on the walls of the one below — not the product inside. Leave 1″–2″ of headroom under a lid and never over-fill above the wall line, or the cap bows and the stack leans.
Turn dimensions into the right spec
Size is only one of three decisions. Wall grade sets strength; capacity sets safe load.
Wall Grades Explained
Single vs. double vs. triple-wall, ECT and burst tests.
Weight Capacities
Static vs. dynamic load, stacking and safety factors.
Condition Grades A–D
How we grade used boxes so you know exactly what you are buying.
Used Gaylord Boxes
Reused inventory in every footprint above.
New Gaylord Boxes
Fresh triple-wall when the job demands it.
Size Guide Hub
Master charts, conversions and the decision matrix.
Gaylord dimension FAQ
What is the most common Gaylord box size?
Why is inside dimension smaller than outside?
How do I calculate the volume of a Gaylord?
How many Gaylords fit in a 53' trailer?
How much strength does overhang cost me?
Can I order a non-standard size?
Right size, first time.
Tell us the load and the pallet — we'll tell you the box.