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Size Guide
Find the perfect gaylord box size for your application. All dimensions are Length x Width x Height in inches.
Pro Tip: The most common size is 48x40x48, designed to fit standard 48x40 GMA pallets used throughout North America.
Need a Custom Size?
We can source or modify boxes to your specifications.
Complete Size Chart
All dimensions in inches (L x W x H). Weight capacities vary by wall type and condition.
| Size (L x W x H) | Volume | Pallet Type | Box Weight | Single Wall | Double Wall | Triple Wall | Applications |
|---|---|---|---|---|---|---|---|
48 x 40 x 48POPULAR 1.51 m³ | 53.3 cu ft | 48x40 Standard GMA | 35 lbs | 600-800 lbs | 1,200-1,500 lbs | 2,000-2,500 lbs | E-commerce, recycling, general warehouse |
48 x 40 x 36POPULAR 1.13 m³ | 40 cu ft | 48x40 Standard GMA | 30 lbs | 500-700 lbs | 1,000-1,300 lbs | 1,800-2,200 lbs | Retail, textiles, lighter materials |
48 x 40 x 24 0.76 m³ | 26.7 cu ft | 48x40 Standard GMA | 25 lbs | 400-600 lbs | 800-1,100 lbs | 1,500-1,900 lbs | Low-profile storage, shipping docks |
48 x 45 x 48 1.70 m³ | 60 cu ft | 48x45 Automotive | 40 lbs | 700-900 lbs | 1,300-1,600 lbs | 2,200-2,700 lbs | Automotive parts, manufacturing |
48 x 48 x 48 1.81 m³ | 64 cu ft | 48x48 Square | 42 lbs | 700-900 lbs | 1,400-1,700 lbs | 2,300-2,800 lbs | Food service, bulk materials |
48 x 40 x 60 1.89 m³ | 66.7 cu ft | 48x40 Standard GMA | 45 lbs | 800-1,000 lbs | 1,500-1,800 lbs | 2,500-3,000 lbs | Large volume items, bulky goods |
40 x 32 x 24 0.50 m³ | 17.8 cu ft | 40x32 Small | 20 lbs | 300-500 lbs | 600-900 lbs | 1,200-1,500 lbs | Small parts, electronics |
44 x 44 x 44 1.39 m³ | 49.1 cu ft | 44x44 Square | 38 lbs | 600-800 lbs | 1,200-1,500 lbs | 2,000-2,400 lbs | Drums, square pallets |
48 x 40 x 42 1.32 m³ | 46.7 cu ft | 48x40 Standard GMA | 32 lbs | 550-750 lbs | 1,100-1,400 lbs | 1,900-2,300 lbs | Mid-height storage, mixed goods |
48 x 42 x 48 1.59 m³ | 56 cu ft | 48x42 Euro | 37 lbs | 650-850 lbs | 1,250-1,550 lbs | 2,100-2,600 lbs | European markets, exports |
Volume Formula
(L × W × H) ÷ 1,728 = cu ftMetric Conversion
1 cu ft = 0.0283 m³Inside Dimensions
All sizes are inside (ID) measurements
Wall Types & Weight Capacity
Understanding wall construction is critical for selecting the right box for your weight requirements.
1
Single Wall
- Thickness
- 3/16" (4.8mm)
- Weight Capacity
- 300-1,000 lbs
- Burst Strength
- 200-275 lbs/sq in
- Edge Crush (ECT)
- 32 ECT
- Reusability
- 1-3 uses
- Cost Factor
- $
- Best For:
- Light goods, one-time use, non-stacking
2
Double Wall
- Thickness
- 3/8" (9.5mm)
- Weight Capacity
- 600-1,800 lbs
- Burst Strength
- 350-500 lbs/sq in
- Edge Crush (ECT)
- 48-51 ECT
- Reusability
- 3-10 uses
- Cost Factor
- $$
- Best For:
- Standard applications, moderate stacking, reuse
3
Triple Wall
- Thickness
- 1/2" (12.7mm)
- Weight Capacity
- 1,200-3,000 lbs
- Burst Strength
- 500-900 lbs/sq in
- Edge Crush (ECT)
- 71-90 ECT
- Reusability
- 5-15 uses
- Cost Factor
- $$$
- Best For:
- Heavy loads, high stacking, demanding use
Weight Capacity Quick Guide
By Product Type:
- Paper/Textiles: 300-800 lbs (Single/Double Wall)
- Plastics/Electronics: 500-1,200 lbs (Double Wall)
- Food Products: 800-1,500 lbs (Double Wall)
- Metal Parts: 1,200-2,500+ lbs (Triple Wall)
Safety Margins:
- Add 20-30% safety margin to your maximum expected weight
- Used boxes: Reduce capacity by 10-30% depending on grade
- Stacking: Bottom box must support all boxes above it
- Humid environments: Reduce capacity by 15-25%
How to Measure Boxes Correctly
Accurate measurements ensure proper pallet fit and prevent costly ordering mistakes.
Step-by-Step Measuring
1
Length (L)
Measure the longest side of the box opening from inside edge to inside edge (front to back)
Tip: Use a metal measuring tape for accuracy
2
Width (W)
Measure the shorter side of the box opening from inside edge to inside edge (side to side)
Tip: Width is typically 40" for standard GMA pallets
3
Height (H)
Measure from the inside bottom of the box to the top of the walls, not including flaps
Tip: Measure at the center, not at corners where it may be compressed
Common Measuring Mistakes
- Measuring outside dimensions instead of inside
- Including flap height in the total height measurement
- Measuring a compressed or damaged corner
- Rounding measurements up or down significantly
Inside vs Outside Dimensions
Our sizes refer to inside dimensions (ID) - the usable space inside the box. Outside dimensions (OD) will be larger depending on wall thickness.
Single Wall:
ID: 48 x 40 x 48" → OD: ~48.4 x 40.4 x 48.4" (adds ~3/8")
Double Wall:
ID: 48 x 40 x 48" → OD: ~48.8 x 40.8 x 48.8" (adds ~3/4")
Triple Wall:
ID: 48 x 40 x 48" → OD: ~49 x 41 x 49" (adds ~1")
Quick Measurement Tools
- Metal Measuring Tape: Most accurate for all dimensions
- Yard Stick: Good for straight-line measurements
- Laser Measure: Fast but may be less accurate on cardboard
Volume Calculations
Understanding box volume helps optimize storage space and shipping costs.
Volume Formula
Cubic Feet (Imperial)
(L × W × H) ÷ 1,728 = cu ft1,728 = cubic inches per cubic foot (12³)
Cubic Meters (Metric)
(L × W × H) ÷ 1,000,000 = m³1,000,000 = cubic cm per cubic meter
Example Calculations:
48 x 40 x 48 Box:
(48 × 40 × 48) ÷ 1,728 = 53.3 cubic feet
Convert to metric: 53.3 × 0.0283 = 1.51 m³
48 x 40 x 36 Box:
(48 × 40 × 36) ÷ 1,728 = 40 cubic feet
Convert to metric: 40 × 0.0283 = 1.13 m³
40 x 32 x 24 Box:
(40 × 32 × 24) ÷ 1,728 = 17.8 cubic feet
Convert to metric: 17.8 × 0.0283 = 0.50 m³
Practical Volume Uses
1
Warehouse Planning
Calculate total storage capacity and optimize floor space usage
2
Shipping Costs
LTL/FTL carriers often charge by cubic feet - know your volume for accurate quotes
3
Inventory Management
Track product density (weight per cubic foot) for better planning
4
Fill Optimization
Determine if you're using 60%, 80%, or 100% of box capacity
Quick Reference
1 cubic foot
0.0283 m³
1 cubic meter
35.31 cu ft
1 inch
2.54 cm
1 pound
0.454 kg
Pallet Compatibility
Matching your gaylord box to the right pallet ensures stability, efficient space usage, and safe transport.
GMA Pallet (48x40)
- Dimensions
- 48" x 40"
- Market Share
- ~80% of US pallets
- Compatible Boxes
- 48 x 40 x 4848 x 40 x 3648 x 40 x 2448 x 40 x 6048 x 40 x 42
- Industries
- General retail, grocery, consumer goods
- Truck Loading
- 24 pallets (2 rows of 12)
European Euro Pallet
- Dimensions
- 48" x 42"
- Market Share
- European standard
- Compatible Boxes
- 48 x 42 x 48
- Industries
- International shipping, exports
- Truck Loading
- 22 pallets
Automotive Pallet
- Dimensions
- 48" x 45"
- Market Share
- Automotive industry
- Compatible Boxes
- 48 x 45 x 48
- Industries
- Auto parts, manufacturing
- Truck Loading
- 20-22 pallets
Square Pallet (48x48)
- Dimensions
- 48" x 48"
- Market Share
- Food service, drums
- Compatible Boxes
- 48 x 48 x 48
- Industries
- Food service, chemical drums
- Truck Loading
- 20 pallets
Small Pallet (40x32)
- Dimensions
- 40" x 32"
- Market Share
- Small parts, retail
- Compatible Boxes
- 40 x 32 x 24
- Industries
- Electronics, small goods
- Truck Loading
- 36 pallets
Square Pallet (44x44)
- Dimensions
- 44" x 44"
- Market Share
- Drums, specialty
- Compatible Boxes
- 44 x 44 x 44
- Industries
- Chemical drums, specialty
- Truck Loading
- 24 pallets
Pallet Fit Guidelines
Perfect Fit (Recommended)
- Box base matches pallet dimensions exactly (±1 inch)
- Maximum stability and safety during transport
- Optimal weight distribution across pallet surface
- Efficient warehouse space utilization
Avoid These Situations
- Box overhangs pallet edges (tipping hazard)
- Box is significantly smaller than pallet (wasted space)
- Mixing different pallet sizes in same warehouse area
- Using non-standard pallets without proper planning
Size Recommendations by Industry
Different industries have unique requirements. Here are our expert recommendations based on typical use cases.
🛒
E-commerce & Retail
- Recommended Sizes:
- 48 x 40 x 4848 x 40 x 36
- Wall Type:
- Double Wall
- Typical Capacity:
- 800-1,200 lbs
- Why This Works:
- High turnover, standard pallet compatibility, good reusability for returns
⚙️
Manufacturing
- Recommended Sizes:
- 48 x 45 x 4848 x 40 x 48
- Wall Type:
- Double/Triple Wall
- Typical Capacity:
- 1,200-2,500 lbs
- Why This Works:
- Heavy parts, automotive compatibility, durability for production lines
🍎
Food & Beverage
- Recommended Sizes:
- 48 x 48 x 4848 x 40 x 48
- Wall Type:
- Double Wall
- Typical Capacity:
- 800-1,500 lbs
- Why This Works:
- Bulk ingredients, regulatory compliance, moisture resistance needed
♻️
Recycling & Waste
- Recommended Sizes:
- 48 x 40 x 4848 x 40 x 60
- Wall Type:
- Single/Double Wall
- Typical Capacity:
- 400-1,000 lbs
- Why This Works:
- High volume collection, cost-effective, standard pallet systems
💻
Electronics
- Recommended Sizes:
- 40 x 32 x 2448 x 40 x 36
- Wall Type:
- Double Wall
- Typical Capacity:
- 500-900 lbs
- Why This Works:
- Smaller parts, protective packaging, controlled environment storage
👕
Textiles & Apparel
- Recommended Sizes:
- 48 x 40 x 3648 x 40 x 48
- Wall Type:
- Single/Double Wall
- Typical Capacity:
- 300-800 lbs
- Why This Works:
- Lightweight goods, volume over weight, frequent handling
💊
Pharmaceuticals
- Recommended Sizes:
- 44 x 44 x 4448 x 40 x 36
- Wall Type:
- Double/Triple Wall
- Typical Capacity:
- 700-1,500 lbs
- Why This Works:
- Clean environment, precise dimensions, regulatory compliance
🚗
Automotive Parts
- Recommended Sizes:
- 48 x 45 x 4848 x 40 x 48
- Wall Type:
- Triple Wall
- Typical Capacity:
- 1,500-2,500 lbs
- Why This Works:
- Heavy metal parts, automotive pallet standard, high durability
Don't see your industry? Contact us for personalized recommendations based on your specific needs.
Stacking Guidelines
Proper stacking maximizes warehouse space while ensuring safety and product integrity.
Safe Stacking Heights
1x
Single Wall Boxes
Maximum: 2-3 boxes high (depending on load)
Total Weight: Up to 2,000-2,500 lbs
Best For: Light materials, one-time shipping
2x
Double Wall Boxes
Maximum: 3-4 boxes high (recommended 3)
Total Weight: Up to 4,000-5,000 lbs
Best For: Standard warehouse operations
3x
Triple Wall Boxes
Maximum: 4-6 boxes high (with proper conditions)
Total Weight: Up to 10,000-12,000 lbs
Best For: Heavy industrial applications
Stacking Best Practices
Level Surface
Always stack on level, stable pallets or floor. Uneven surfaces cause instability and box failure.
Even Weight Distribution
Fill boxes evenly. Heavy loads in corners cause bulging and structural failure.
Align Edges
Stack boxes directly on top of each other with edges aligned. Offset stacking reduces strength by 30-50%.
Heaviest on Bottom
Place heaviest boxes at the bottom of the stack. Lighter boxes cannot support heavy loads above.
Climate Control
High humidity (>60%) reduces strength by 20-30%. Keep boxes in climate-controlled areas when possible.
Regular Inspection
Check bottom boxes weekly for bulging, crushing, or moisture damage. Replace compromised boxes immediately.
Safety Warnings
- !Never exceed manufacturer-rated weight capacity
- !Don't stack boxes higher than forklift reach height
- !Reduce stacking height if floors are uneven or sloped
- !Used boxes: reduce stack height by 1-2 boxes depending on grade
Stacking Capacity Calculator
2-3
Boxes High
Single Wall
~2,000-2,500 lbs total
~2,000-2,500 lbs total
3-4
Boxes High
Double Wall
~4,000-5,000 lbs total
~4,000-5,000 lbs total
Most Common
4-6
Boxes High
Triple Wall
~10,000-12,000 lbs total
~10,000-12,000 lbs total
Storage Space Calculations
Plan your warehouse layout and maximize storage efficiency with these calculations.
Floor Space Requirements
Formula:
(L × W) ÷ 144 = sq ft per box144 = square inches per square foot (12 × 12)
Common Box Footprints:
48 × 40
Standard GMA
13.3 sq ft
per box
48 × 48
Square
16 sq ft
per box
40 × 32
Small
8.9 sq ft
per box
48 × 45
Automotive
15 sq ft
per box
Example Calculation:
1,000 sq ft warehouse × 0.75 (usable space) = 750 sq ft
750 sq ft ÷ 13.3 sq ft per box = ~56 boxes (48×40)
If stacked 3 high: 168 total boxes
Warehouse Efficiency Factors
Aisle Space-25% to -40%
Forklift aisles typically 10-12 feet wide
Staging Areas-10% to -15%
Loading, unloading, and sorting zones
Column/Obstruction-5% to -10%
Building columns, utilities, offices
Safety Clearance-5% to -10%
Fire codes, emergency exits, sprinklers
Typical Usable Space:
65-75%
of total warehouse square footage
Vertical Storage Optimization
12-16 ft ceilings: Stack 2-3 boxes high (most common)
20-24 ft ceilings: Stack 3-5 boxes high (requires reach forklift)
Pallet racking: Can triple capacity with proper equipment
Always leave 24-36 inches clearance below ceiling for sprinklers
Quick Capacity Estimator
| Warehouse Size | Usable Space (70%) | 48×40 Boxes (1 high) | Stacked 3 High |
|---|---|---|---|
| 1,000 sq ft | 700 sq ft | ~52 boxes | ~156 boxes |
| 2,500 sq ft | 1,750 sq ft | ~131 boxes | ~393 boxes |
| 5,000 sq ft | 3,500 sq ft | ~263 boxes | ~789 boxes |
| 10,000 sq ft | 7,000 sq ft | ~526 boxes | ~1,578 boxes |
| 20,000 sq ft | 14,000 sq ft | ~1,052 boxes | ~3,156 boxes |
* Estimates based on 48×40 boxes (13.3 sq ft each) with 70% usable warehouse space
Standard vs Custom Sizes
Understanding when to use standard sizes versus custom solutions can save you time and money.
Standard Sizes
Advantages:
- Immediately Available: Stock items ship within 1-3 business days
- Lower Cost: 30-60% less expensive than custom sizes
- No Minimums: Order as few as 5-10 boxes (used) or 50+ (new)
- Pallet Compatible: Fits standard 48×40 GMA pallets
- Easy Resale: High demand for used standard sizes
- Flexibility: Works for 80% of applications
Best For:
- General warehouse operations
- Startups and small businesses
- Variable or seasonal needs
- Quick turnaround requirements
Most Popular Standard Sizes:
48 × 40 × 4848 × 40 × 3648 × 40 × 24
Custom Sizes
Advantages:
- Perfect Fit: Exact dimensions for your specific needs
- Space Optimization: Maximize storage efficiency
- Custom Features: Add handles, labels, coatings, etc.
- Branding: Custom printing and colors available
- Unique Pallets: Match non-standard pallet sizes
- Specialty Materials: Moisture-resistant, food-grade, etc.
Considerations:
- Lead Time: 6-12 weeks for new manufacturing
- Minimum Orders: Typically 500-1,000+ units for manufacturing
- Higher Cost: 30-60% premium over standard sizes
- Limited Resale: Harder to resell custom dimensions
Best For:
- Large-scale operations (500+ boxes/year)
- Unique pallet or rack systems
- Specialty product requirements
- Brand differentiation needs
Alternative: Modified Standard
We can often modify standard boxes (height adjustments, add features) with lower minimums (100-250 units) and faster turnaround (2-4 weeks).
Need Help Deciding?
Our team can help you determine whether standard or custom sizes are right for your application. We'll analyze your needs, volume, timeline, and budget to recommend the best solution.
Get Expert AdviceFrequently Asked Questions
Common questions about gaylord box sizes and specifications.
What is the most common gaylord box size?
The 48x40x48 inch size is by far the most common, representing about 70% of all gaylord boxes used in North America. It's designed to fit perfectly on the standard GMA pallet (48x40 inches) used throughout the US and Canada.
How do I calculate the volume of a gaylord box?
Multiply Length x Width x Height (in inches), then divide by 1,728 to get cubic feet. Formula: (L x W x H) / 1,728 = cubic feet. For example: (48 x 40 x 48) / 1,728 = 53.3 cubic feet. For metric, multiply in centimeters and divide by 1,000,000 for cubic meters.
Can I stack gaylord boxes when they are full?
Yes, but it depends on the wall type and load. Double wall boxes can typically support 2-3 boxes stacked (up to 3,000-4,000 lbs), while triple wall can handle 4-5 boxes (up to 8,000-10,000 lbs). Always consider the bottom box's weight capacity and ensure even weight distribution.
What weight capacity should I choose?
Choose based on your heaviest expected load plus 20-30% safety margin. Single wall (up to 800 lbs) for light items, double wall (up to 1,500 lbs) for most applications, and triple wall (up to 2,500+ lbs) for heavy industrial use. Consider stacking requirements too.
Do you measure inside or outside dimensions?
Standard gaylord box dimensions refer to inside dimensions (ID) - the usable space. Outside dimensions (OD) are larger depending on wall thickness: single wall adds ~3/8", double wall adds ~3/4", triple wall adds ~1". A 48x40x48 ID double wall box measures approximately 49x41x49 OD.
How many gaylord boxes fit on a truck?
On a standard 53-foot trailer: 24 boxes for 48x40 pallets (2 rows of 12), 20 boxes for 48x45 or 48x48 pallets, 36 boxes for 40x32 pallets. Height depends on trailer clearance (typically 110 inches), so 48-inch tall boxes are most common.
Can I get custom sizes?
Yes! While custom manufacturing requires large minimums (typically 500-1,000+ units), we can often source or modify existing boxes for custom sizes. Common modifications include height adjustments, reinforced corners, or custom pallet bases. Contact us to discuss your needs.
What is the difference between new and used boxes?
New boxes have full structural integrity and weight capacity. Used boxes (typically 1-5 prior uses) are graded: Grade A (like new, 90-100% capacity), Grade B (good condition, 70-90% capacity), Grade C (visible wear, 50-70% capacity). Used boxes cost 40-70% less than new.
How long can I store items in a gaylord box?
In climate-controlled, dry storage: indefinitely for most goods. Corrugated cardboard maintains strength when kept dry. However, avoid humid environments (>60% humidity), direct floor contact (use pallets), and prolonged sun exposure. For long-term outdoor storage, use weather-resistant coatings.
What size should I use for my warehouse?
Consider: 1) Your pallet system (match box base to pallet size), 2) Ceiling height (leave 24" clearance for forklifts), 3) Racking systems (factor in rack height/depth), 4) Product weight (heavier = lower height), 5) Handling equipment (ensure forklift clearance). The 48x40x48 offers the best versatility.
How do I prevent boxes from bulging?
Bulging occurs from overfilling or improper stacking. Prevent by: 1) Don't exceed 80% capacity, 2) Use wall type appropriate for weight, 3) Fill evenly without overloading corners, 4) Don't stack too high (max 5-6 boxes), 5) Place heavier items at the bottom, 6) Use stretch wrap or banding for stability.
Are gaylord boxes recyclable?
Yes! Gaylord boxes are made from corrugated cardboard (kraft paper), which is highly recyclable. At end of life, they can be broken down and recycled at standard cardboard recycling facilities. Many companies reuse them multiple times before recycling, making them environmentally friendly packaging solutions.
Have a question not answered here? Contact our team - we're here to help!
Can't Find Your Size?
Contact us - we can source custom sizes or modify existing boxes to meet your needs.
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