Size chart · gaylords
Ten sizes, inside and outside.
The inside number is the one your product has to fit into. The outside number is the one that has to fit your pallet, your rack and your trailer. Confusing the two is the most expensive mistake in this trade.
Quote a gaylord size
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Add for triple wall
Roughly 5/8" of board per side, so 1.25" on every axis. A 48 × 40 × 36 inside becomes about 49.25 × 41.25 × 37.25 outside — which is why a “flush” gaylord overhangs a GMA pallet.
The master table
Inside, outside, cube, capacity, flat cube and trailer count.
Flat cube assumes knocked down and banded; trailer counts assume a 53-foot dry van at 72% packing efficiency.
| Size | Inside (L×W×H) | Outside, approx. | Cube | Capacity | Wall | Grades |
|---|---|---|---|---|---|---|
| Standard 48 | 48" × 40" × 36" | 49.25" × 41.25" × 37.25" | 40.0 ft³ | 1,800 – 2,200 lb | Triple wall | A / B |
| Low-side 48 | 48" × 40" × 30" | 49.25" × 41.25" × 31.25" | 33.3 ft³ | 1,600 – 2,000 lb | Triple wall | A / B |
| Mid 48 | 48" × 40" × 34" | 49.25" × 41.25" × 35.25" | 37.8 ft³ | 1,800 lb | Triple wall | B |
| Tall-standard 48 | 48" × 40" × 39" | 49.25" × 41.25" × 40.25" | 43.3 ft³ | 1,900 lb | Triple wall | A / B |
| Tall 48 | 48" × 40" × 44" | 49.25" × 41.25" × 45.25" | 48.9 ft³ | 1,800 – 2,200 lb | Triple wall | A / B / C |
| Extra-tall 48 | 48" × 40" × 48" | 49.25" × 41.25" × 49.25" | 53.3 ft³ | 2,000 – 2,400 lb | Triple wall | B / C |
| Column 48 | 48" × 40" × 52" | 49.25" × 41.25" × 53.25" | 57.8 ft³ | 2,000 lb | Triple wall + corner posts | B |
| Harvest 48 | 48" × 40" × 60" | 49.25" × 41.25" × 61.25" | 66.7 ft³ | 2,200 lb | Triple wall + liner | A |
| Wide 48 | 48" × 44" × 36" | 49.25" × 45.25" × 37.25" | 44.0 ft³ | 2,000 lb | Triple wall | A / B |
| Produce 48 | 48" × 45" × 34" | 49.25" × 46.25" × 35.25" | 42.5 ft³ | 1,900 lb | Triple wall, vented | A |
| Pallet-flush 40 | 40" × 48" × 40" | 41.25" × 49.25" × 41.25" | 44.4 ft³ | 1,200 – 1,500 lb | Double wall | B |
| Octabin 41 | 41" × 41" × 45" | 42.25" × 42.25" × 46.25" | 43.7 ft³ | 2,000 – 2,800 lb | Double / triple wall (8-sided) | A / B |
| Octabin 41 | 41" × 41" × 38" | 42.25" × 42.25" × 39.25" | 36.9 ft³ | 2,400 lb | Triple wall (8-sided) | A / B |
| Tall octabin | 41" × 41" × 53" | 42.25" × 42.25" × 54.25" | 51.5 ft³ | 2,000 lb | Double wall (8-sided) | B |
| Compact 36 | 36" × 36" × 36" | 37.25" × 37.25" × 37.25" | 27.0 ft³ | 900 – 1,200 lb | Double wall | B / C |
| Compact tall | 36" × 36" × 45" | 37.25" × 37.25" × 46.25" | 33.8 ft³ | 1,000 lb | Double wall | B / C |
| Half-pallet 32 | 32" × 30" × 36" | 33.25" × 31.25" × 37.25" | 20.0 ft³ | 800 lb | Double wall | B |
| Mini bulk | 30" × 30" × 30" | 31.25" × 31.25" × 31.25" | 15.6 ft³ | 700 lb | Double wall | B |
| Quarter bin | 24" × 20" × 21" | 25.25" × 21.25" × 22.25" | 5.8 ft³ | 350 lb | Double wall | B / C |
| Shallow 48 | 48" × 40" × 24" | 49.25" × 41.25" × 25.25" | 26.7 ft³ | 1,500 lb | Triple wall | A / B |
Choosing by density
Tall boxes for light material. Low boxes for heavy.
This is the single most useful rule on this page. A tall container filled with dense material fails at the corners long before the board is worn out.
| Material | Approx. density | Recommended height | Why |
|---|---|---|---|
| Metal turnings, castings | 90 – 180 lb/ft³ | 30" low-side | Weight limit reached at a third of the cube; a tall box just invites corner failure |
| Baled textiles, rags | 25 – 40 lb/ft³ | 36" standard | Balanced load and cube |
| Mixed OCC collection | 8 – 15 lb/ft³ | 44" tall | Cube-limited, not weight-limited |
| Foam, void fill, film | 2 – 6 lb/ft³ | 48" extra-tall | Pure volume; weight is irrelevant |
| Produce, agricultural bulk | 30 – 45 lb/ft³ | 36" wide (48×44) | Needs footprint more than height |
| Hemp, tobacco biomass | 6 – 12 lb/ft³ | 60" harvest bin, lined | Maximum cube per pallet position |
| Resin pellets, powders | 35 – 60 lb/ft³ | 45" octabin | Eight sides handle hoop stress and empty cleanly |
The number almost nobody asks for: flat cube.
A 48 × 40 × 36 triple-wall gaylord occupies 40 cubic feet erected and about 4.7 knocked down. On a single 53-foot trailer that is 62 boxes versus 534.
Box Studio computes it for any size, including the blank area and board weight.
Pallet footprints
Eight decks, and what sits on them.
Specify your container to the pallets you actually own, not to the standard. A 48 × 40 GMA pallet in the real world runs anywhere from 47.5 to 48.5 inches.
| Footprint | Construction | Typical use | Note |
|---|---|---|---|
| 48" × 40" GMA, 4-way | Stringer, notched | North American standard | Real examples run 47.5 – 48.5 inches. Measure yours. |
| 48" × 40" block | Block, 4-way true | Automated handling | Better for AS/RS and robotics |
| 48" × 48" drum | Stringer | Chemical, octabins | Suits the 41-inch octabin footprint |
| 42" × 42" | Stringer | Beverage, telecom | Common in soft-drink distribution |
| 48" × 45" | Stringer | Produce field pack | Matches vented produce bins |
| 36" × 36" half | Block | Retail display | Store-level display base |
| 1200 × 1000 mm | Block | International | The closest metric equivalent to GMA |
| 1200 × 800 mm EUR | Block | Europe | Too narrow for most US bulk containers |
| Pattern | Compression retained | Stability | Wrap needed | Use when |
|---|---|---|---|---|
| Column (aligned) | Up to 100% | Low | Required | Heavy uniform loads into racking |
| Brick (offset rows) | ~60% | Good | Recommended | Mixed weight, manual handling |
| Pinwheel | ~60 – 70% | Highest | Recommended | Odd footprints with a centre void |
| Full interlock | ~45% | Highest | Optional | Light loads where toppling is the risk |
Equipment dimensions
What actually fits in the truck.
Every cube figure we quote is calculated against these, at a realistic 72% packing efficiency rather than a theoretical 100%.
| Unit | Inside dimensions | Volume | Pallet positions | Payload | Note |
|---|---|---|---|---|---|
| 53' dry van | 630" × 100" × 110" | 3,489 ft³ | 26 | 45,000 lb | Our standard outbound unit |
| 48' dry van | 576" × 99" × 108" | 3,100 ft³ | 24 | 44,000 lb | Older fleet, still common on LTL |
| 28' pup | 330" × 100" × 108" | 1,750 ft³ | 12 | 22,000 lb | LTL linehaul segment |
| 26' straight truck | 306" × 96" × 96" | 1,700 ft³ | 12 | 10,000 lb | Liftgate deliveries to sites without docks |
| 40' container | 474" × 92" × 94" | 2,390 ft³ | 20 | 59,000 lb | Export; corrugated avoids ISPM 15 |
| 40' high cube | 474" × 92" × 106" | 2,694 ft³ | 20 | 58,000 lb | Preferred for low-density freight |
Liners
Eleven liners, and what each one is actually for.
For most bulk applications the liner matters more than the board. It carries the moisture barrier, the food-contact claim and — for powders — the static behaviour.
| Type | Gauge | Barrier | Relative cost | Suited to | Note |
|---|---|---|---|---|---|
| Standard poly | 2 – 4 mil | Moisture | 1.0× | Resin pellets, granulate, general bulk | Clear, so fill level is visible from outside |
| Heavy poly | 6 mil | Moisture, puncture | 1.6× | Sharp or abrasive granulate | Resists puncture from angular material |
| Antistatic poly (topical) | 4 mil | Moisture, static | 1.4× | General dust control | Stops working below ~30% relative humidity |
| Antistatic poly (permanent) | 4 mil | Moisture, static | 2.1× | Dry or heated facilities | Additive integral to the film; humidity-independent |
| Static dissipative | 4 – 6 mil | Controlled discharge | 3.0× | Electronics feedstock | Needs a verified grounding path to work |
| Conductive / Type C | 6 mil | Grounded discharge | 4.2× | Combustible dust | Only safe as part of a bonded, grounded system |
| Foil laminate | — | Moisture, light, vapour | 3.4× | Humidity-sensitive powders | Opaque; fill level needs a separate check |
| Multi-layer odour barrier | — | Moisture, odour | 3.8× | Hemp, cannabis, aromatics | EVOH or metallised layer; plain poly will not do this |
| FDA-compliant poly | 2 – 6 mil | Moisture, food contact | 1.3× | Food ingredients, pet food | Supplied with a letter of guarantee |
| Spouted liner | 4 mil | Moisture | 1.9× | Gravity discharge lines | Bottom spout; halves emptying time |
| Vented liner | 2 mil | Partial | 1.5× | Respiring produce and biomass | Closed but not sealed — stops internal humidity build-up |
Board weight
What a square foot of each build actually weighs.
The number you need to turn a die-line area into a shipping weight, a carbon figure or a freight class. Multiply blank area in square feet by the figure below.
| Construction | lb per ft² | lb per MSF | Caliper | Note |
|---|---|---|---|---|
| Single wall, 32 ECT (C flute) | 0.20 | 200 | 0.16" | Lightest practical shipper |
| Single wall, 44 ECT (C flute) | 0.24 | 240 | 0.17" | Heavier liner, same flute |
| Double wall, 48 ECT (BC) | 0.33 | 330 | 0.30" | The reuse workhorse |
| Double wall, 61 ECT (BC) | 0.40 | 400 | 0.32" | Heavy distribution |
| Triple wall, 71 ECT | 0.48 | 480 | 0.52" | Crate replacement |
| Triple wall, 1,100 lb test | 0.55 | 550 | 0.60" | Gaylord standard |
| Honeycomb panel, 1" | 0.35 – 0.60 | — | 1.00" | Dunnage and display substrate |
Storage
What the rack does to the box.
Container specification and racking choice are the same decision made twice. Drive-in and push-back racking are where we see the most container damage, because the container is handled blind.
| Rack type | Beam span | Load capacity | Effect on containers |
|---|---|---|---|
| Selective pallet rack | 96 – 144" | 2,500 – 6,000 lb/level | Most common; one pallet deep |
| Double deep | 96 – 108" | 2,500 – 5,000 lb/level | Needs a reach truck; container squareness critical |
| Drive-in | N/A, rails | 2,000 – 4,000 lb/pallet | Container damage risk is highest here |
| Push-back | 96 – 120" | 2,200 – 4,500 lb/pallet | Dynamic load; overhang is unforgiving |
| Pallet flow | 96 – 120" | 2,000 – 3,000 lb/pallet | Bottom-board condition decides whether it rolls |
| Floor stacking | N/A | Board-limited | Where box compression strength actually binds |
| Item | Limit | Note |
|---|---|---|
| Single-person lift, ideal zone | Up to 35 lb | Between knuckle and shoulder height, close to the body |
| Single-person lift, absolute | 50 lb | Common carrier and insurer threshold for cartons |
| Two-person lift | Up to 100 lb | Requires clear path and matched heights |
| Carton max gross, 32 ECT | 65 lb | Certificate limit, not a handling recommendation |
| Carton max gross, 48 ECT | 120 lb | Mechanical handling expected |
| Gaylord, loaded | 1,800 – 2,400 lb | Forklift or pallet truck only |
| Pallet jack, manual | 5,500 lb | Flat floors only |
| Counterbalance forklift, typical | 5,000 lb at 24" load centre | Derates sharply as load centre moves out |
Freight class
Why empty packaging rates so badly.
LTL pricing keys off density. Knocked-down corrugated weighs almost nothing and occupies a full pallet position, so it lands near the expensive end of a scale designed around weight.
| Class | Density | Typical commodity | Where packaging sits |
|---|---|---|---|
| 50 | 50+ lb/ft³ | Bricks, steel bar | Rarely packaging |
| 55 | 35 – 50 | Hardwood flooring | Dense palletised goods |
| 60 | 30 – 35 | Car accessories | Heavy cartoned goods |
| 65 | 22.5 – 30 | Bottled beverages | Full case packs |
| 70 | 15 – 22.5 | Food in cartons | Typical dense distribution |
| 85 | 12 – 15 | Crated machinery | Palletised assemblies |
| 92.5 | 10.5 – 12 | Computers, monitors | Cushioned electronics |
| 100 | 9 – 10.5 | Boat covers, canvas | Light bulky goods |
| 125 | 7 – 8 | Small appliances | Void-filled cartons |
| 150 | 6 – 7 | Auto sheet metal | Erected boxes start here |
| 175 | 5 – 6 | Clothing, couches | Knocked-down heavy board |
| 200 | 4 – 5 | Aircraft parts | Knocked-down double wall |
| 250 | 3 – 4 | Mattresses, plasma TVs | Knocked-down single wall |
| 300 | 2 – 3 | Wood cabinets, tables | Erected gaylords |
| 400 | 1 – 2 | Deer antlers | Erected light bulk |
| 500 | < 1 | Gold dust, ping-pong balls | Loose void fill |
Note the two rows that matter here: knocked-down board is class 150 – 250, erected containers are class 300 – 400. That gap is the entire argument for banding everything flat.
Receiving
Seven things about your dock that change the quote.
Declared before the quote these are free to plan around. Discovered on delivery day they are the single most common reason a cheap quote becomes an expensive invoice.
| Item | Specification | Why it matters |
|---|---|---|
| Dock height | 48 – 52" typical | Below 44" a standard trailer needs a leveller or a ramp |
| Dock leveller capacity | 20,000 – 30,000 lb | Loaded gaylords on a pallet truck approach the limit |
| Door width | 8 – 9 ft | Double-stacked knocked-down bundles are wide |
| Apron depth | 100 – 130 ft | A 53-foot trailer needs room to square up |
| Liftgate requirement | If no dock | Add $75 – $150; declare it before the quote, not after |
| Receiving window | 3-day window ideal | Lets us consolidate; worth more than a volume discount |
| Forklift availability | 3,000 lb minimum | A loaded gaylord plus pallet exceeds many electric walkies |