Size Guide
Everything you need to know about gaylord box dimensions, wall types, weight ratings, and how to choose the right size for your application.
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Gaylord Box Size Chart
All standard gaylord box sizes with inside dimensions, weight capacities, wall types, and pallet compatibility. Sizes are listed in inside dimensions (L x W x H) in inches.
| Common Name | Dimensions (L x W x H) | Volume (cu ft) | Weight Capacity | Wall Type | Pallet Fit |
|---|---|---|---|---|---|
Full-Size Gaylord Standard Pallet | 48" x 40" x 36" | 40 ft³ | 1,200 - 2,500 lbs | Double / Triple | Standard 48x40 GMA Pallet |
Tall Gaylord Tall Standard | 48" x 40" x 48" | 53.3 ft³ | 1,000 - 2,200 lbs | Double / Triple | Standard 48x40 GMA Pallet |
Short Gaylord / Half-Height Low Profile | 48" x 40" x 24" | 26.7 ft³ | 1,500 - 2,800 lbs | Double / Triple | Standard 48x40 GMA Pallet |
Wide Gaylord Wide Body | 48" x 45" x 36" | 45 ft³ | 1,200 - 2,400 lbs | Double / Triple | 48x45 Automotive Pallet |
Jumbo Gaylord / Oversize Jumbo | 58" x 42" x 45" | 63.5 ft³ | 1,000 - 2,000 lbs | Triple | Custom / Oversize Pallet |
Cube Gaylord / Square Cube | 36" x 36" x 36" | 27 ft³ | 1,000 - 2,000 lbs | Double / Triple | 36x36 Pallet or Custom |
Narrow Gaylord Narrow | 48" x 36" x 36" | 36 ft³ | 1,200 - 2,200 lbs | Double / Triple | 48x36 Pallet or Overhang on 48x40 |
Extra Tall Gaylord Extra Tall | 48" x 40" x 60" | 66.7 ft³ | 800 - 1,800 lbs | Triple | Standard 48x40 GMA Pallet |
Mini Gaylord / Half Pallet Half Pallet | 24" x 20" x 24" | 6.7 ft³ | 500 - 1,000 lbs | Double | Half Pallet (24x20) |
Produce Gaylord / Medium Produce Standard | 48" x 40" x 30" | 33.3 ft³ | 1,400 - 2,600 lbs | Double / Triple | Standard 48x40 GMA Pallet |
Full-Size Gaylord
48" x 40" x 36"The most widely used gaylord box size in North America. Compatible with virtually all warehouse racking, loading docks, and freight carriers. This is the size most people mean when they say gaylord box.
Tall Gaylord
48" x 40" x 48"33% more volume than the standard 36-inch height. Ideal for lightweight, bulky products like plastics, foam, textiles, and insulation. Height may limit double-stacking in standard trailers.
Short Gaylord / Half-Height
48" x 40" x 24"Lower center of gravity provides superior stability for heavy, dense materials. Excellent for metal parts, hardware, and glass. Allows triple-stacking in most standard trailers.
Wide Gaylord
48" x 45" x 36"5 inches wider than standard, designed for the automotive and manufacturing industries that use 48x45 pallets. Common in auto parts plants and heavy industrial applications.
Jumbo Gaylord / Oversize
58" x 42" x 45"The largest commonly available size. Massive volume for bulky, lightweight materials like plastic bottles, foam packing, and insulation. Requires oversize pallets and wider dock doors.
Cube Gaylord / Square
36" x 36" x 36"Equal dimensions on all sides provide balanced stacking. Popular for retail distribution, food service, and applications where uniformity matters. Fits two across on a standard 48-inch pallet.
Narrow Gaylord
48" x 36" x 36"Slightly narrower than standard, useful for space-constrained applications. Works well in narrow-aisle warehousing and when contents require a specific width for nesting or alignment.
Extra Tall Gaylord
48" x 40" x 60"Maximum volume for extremely lightweight products. Common in recycling facilities for collecting plastic film, packaging peanuts, and shredded paper. Single-stack only in most trailers.
Mini Gaylord / Half Pallet
24" x 20" x 24"Exactly one-quarter the footprint of a standard gaylord. Ideal for smaller quantities, sample shipments, and operations with limited floor space. Four fit on a single standard pallet.
Produce Gaylord / Medium
48" x 40" x 30"A popular size in agriculture and food processing. The 30-inch height balances volume with easy reach-in access for sorting and inspection. Supports double-stacking in standard trailers.
How to Measure Gaylord Boxes
Accurate measurement is essential for selecting the right box, ensuring pallet compatibility, and calculating shipping costs. Follow these guidelines to measure any gaylord box correctly.
Always Measure Inside Dimensions
Gaylord box sizes are expressed as inside dimensions, meaning the usable space inside the box. Outside dimensions will be slightly larger depending on wall thickness. When comparing sizes or calculating how much product will fit, always use inside measurements. A 48x40x36 box has 48 inches of usable length, 40 inches of usable width, and 36 inches of usable height on the inside.
Length x Width x Height (L x W x H)
Dimensions are always listed in the order Length x Width x Height. Length is the longest side of the opening. Width is the shorter side of the opening. Height is measured from the bottom of the box to the top of the walls. For used boxes, always verify dimensions with a tape measure because repeated use can cause slight dimensional changes.
Account for Flap Overlap
The stated height of a gaylord box measures the walls only, not including the flaps. When the flaps are closed, they overlap and add additional height. For full-bottom boxes, measure from the inside bottom surface to the top of the walls for the true usable height. For boxes with flap bottoms, the overlap creates a slightly raised floor.
Check for Squareness
Used gaylord boxes may develop slight dimensional irregularities through repeated use. Before relying on published dimensions for tight-tolerance applications, measure the actual box diagonally across the opening. If both diagonal measurements are equal, the box is square. A difference of more than one inch may affect product fit and stacking stability.
Measure Wall Thickness
If you need to verify whether a box is single, double, or triple wall, cut a small section from a flap edge and count the layers of fluted medium. Single wall has one wavy layer, double wall has two, and triple wall has three. You can also measure the total thickness: single wall is roughly 1/8 to 3/16 inch, double wall is about 1/4 inch, and triple wall is 3/8 to 1/2 inch.
Consider Pallet Compatibility
Always verify that your gaylord box dimensions match your pallet size. A standard 48x40 box should sit flush on a 48x40 GMA pallet with no overhang. Overhang beyond the pallet edge creates safety hazards during forklift transport and can cause product damage. If your box is larger than your pallet, upgrade to the correct pallet size.
Wall Types Explained
The number of corrugated walls determines a gaylord box's strength, weight capacity, and cost. Understanding wall types is essential for selecting the right box for your application. Here is a detailed breakdown of every wall type available.
Single Wall
Single-wall corrugated consists of one fluted medium sandwiched between two flat liner boards. This is the most common corrugated construction found in standard shipping boxes but is relatively rare in gaylord boxes because it lacks the strength needed for bulk container applications. When single-wall construction is used in gaylords, it is typically reserved for very lightweight applications such as collecting plastic film, packing peanuts, or other materials that weigh less than 500 pounds total.
Double Wall
Double-wall corrugated is the standard construction for most gaylord boxes. It features two layers of fluted medium separated by a flat liner, with additional liner boards on the outside faces. The BC flute combination provides an excellent balance of stacking strength, puncture resistance, and weight. Double-wall gaylords handle the vast majority of industrial, commercial, and distribution applications reliably. This is the most cost-effective choice for contents weighing up to 1,500 to 2,000 pounds.
Triple Wall
Triple-wall corrugated is the heavy-duty option, featuring three layers of fluted medium for maximum strength. This construction is used for the most demanding gaylord box applications: heavy automotive parts, metal components, dense recyclables, and any load exceeding 2,000 pounds. Triple-wall gaylords offer stacking compression strength comparable to wooden crates at a fraction of the weight. They also provide superior puncture resistance, making them ideal for sharp or irregular contents.
4-Wall (Quad Wall)
Four-wall corrugated construction adds a fourth fluted layer for extreme strength requirements. This is a specialty product not commonly stocked but available through custom orders. Quad-wall gaylords are used in very specific heavy industrial applications such as shipping heavy machinery components, dense chemical products in lined containers, and military specification packaging where maximum burst and compression strength are required.
5-Wall (Penta Wall)
Five-wall corrugated is the most robust corrugated construction available, essentially a wood-crate replacement. At nearly an inch thick, penta-wall gaylord boxes can handle loads exceeding 4,000 pounds and provide stacking strength that rivals traditional wooden crates and palletized containers. These are custom-manufactured products with longer lead times and higher costs, but they are the only corrugated option for the heaviest, most demanding shipping and storage applications.
Weight Ratings
Gaylord boxes are classified into weight rating tiers based on their wall construction and edge crush test (ECT) ratings. Choosing the correct weight rating prevents box failure, product damage, and workplace safety hazards.
Light Duty
Up to 800 lbs — Single or Light Double WallLight-duty rated gaylord boxes are suitable for contents weighing less than 800 pounds. This includes lightweight materials like plastic film, foam products, empty bottles, textile scraps, and packing materials. Light-duty boxes use thinner corrugated construction and are the most affordable option when weight is not a concern.
Standard Duty
800 - 1,500 lbs — Double Wall (BC Flute)Standard-duty is the most common rating for gaylord boxes used in general commercial and industrial applications. This covers the majority of products shipped in bulk containers: mixed recyclables, consumer goods, food products, moderate-weight manufactured parts, and general warehouse storage. Double-wall BC flute construction is the standard for this weight range.
Heavy Duty
1,500 - 2,500 lbs — Triple Wall (BC + E Flute)Heavy-duty gaylord boxes are engineered for demanding applications where standard-duty boxes are not strong enough. Automotive parts, metal stampings, hardware, dense agricultural products, and heavy recyclables like glass all require heavy-duty construction. Triple-wall construction provides the burst strength and stacking compression needed to handle these loads safely.
Extra Heavy Duty
2,500 - 4,000+ lbs — Quad or Penta WallExtra heavy-duty gaylord boxes use four- or five-wall corrugated construction for the most extreme weight requirements. These are specialty products used for applications like shipping dense machinery components, heavy castings, and bulk chemical products. At this weight level, corrugated gaylord boxes serve as a lighter, more sustainable alternative to wooden crates and rigid plastic containers.
Choosing the Right Size
Not sure which gaylord box size is right for your application? Here are our recommendations based on common use cases. Our team is always available to provide personalized sizing guidance based on your specific requirements.
General Warehousing & Distribution
48" x 40" x 36" Double WallFor standard warehousing, distribution, and shipping applications, the 48x40x36 double-wall gaylord is the industry default. It fits standard pallets, standard racking, and standard trailers. Unless you have specific requirements that dictate otherwise, this is the size to start with.
Lightweight Bulky Products
48" x 40" x 48" or 48" x 40" x 60" Triple WallFor lightweight, high-volume products like plastic bottles, foam, textiles, or packing materials, taller boxes maximize the amount of product per pallet position. Triple-wall construction is recommended for the taller sizes to maintain structural integrity even though the contents are light.
Heavy Industrial Parts
48" x 40" x 24" Triple WallFor heavy metal parts, automotive components, glass, and dense materials, the low-profile 24-inch height keeps the center of gravity low and allows safe stacking. Triple-wall construction is essential for contents exceeding 1,500 pounds to ensure burst strength and compression resistance.
Automotive Manufacturing
48" x 45" x 36" Triple WallThe automotive industry standardized on the 48x45 pallet footprint. If you operate in automotive supply chain, this slightly wider gaylord ensures flush fit with automotive pallets. Triple wall is standard in this industry due to the weight of typical automotive parts and components.
Agriculture & Produce
48" x 40" x 30" Double WallThe 30-inch height is preferred for agricultural applications because it allows easy reach-in access for sorting and inspection while still providing adequate volume. Double-wall construction is usually sufficient since produce is typically moderate in weight. Use food-grade liners when required.
Recycling Collection
48" x 40" x 48" Double Wall (Grade C or D)Recycling collection does not require premium appearance, so Grade C or D used boxes are the most cost-effective choice. The taller 48-inch height maximizes collection volume per box. Double wall is sufficient since recyclable materials are typically lightweight. Replace boxes when walls become soft.
Small Batch & Samples
36" x 36" x 36" or 24" x 20" x 24" Double WallFor smaller quantities, sample shipments, or operations with limited floor space, smaller gaylord sizes offer the same functionality in a more manageable package. The 36x36x36 cube fits two across on a standard pallet, while the 24x20x24 mini fits four per standard pallet.
E-Commerce Returns Processing
48" x 40" x 36" Double Wall (Grade B or C)Returns processing benefits from the standard 48x40x36 size because it maximizes volume while remaining compatible with all standard equipment. Grade B or C boxes offer the best balance of cost and durability for this application where appearance is less critical than function.
Need Help Choosing the Right Size?
Our sizing experts have helped thousands of businesses find the perfect gaylord box for their application. Tell us what you are packing, how much it weighs, and where it is going, and we will recommend the ideal size, wall type, and grade combination for your needs.