48×40×40
Most common tri-wall footprint (cubic volume ≈ 44.4 ft³)
3,000 lb
Typical maximum load for triple-wall boxes on pallets
26-28
Gaylords per 53 ft trailer (standard pallet orientation)
Gather These Inputs Before Calculating
Dimensions
- Internal length & width (inches)
- Usable internal height (inches)
- Wall thickness (single/double/triple)
Material & contents
- Product bulk density (lb/ft³)
- Desired headspace clearance (%)
- Moisture or plastic liner usage
Handling environment
- Forklift vs. pallet jack handling
- Warehouse stacking height
- Transit conditions (LTL, TL, export)
Volume & Weight Conversions
Volume (ft³) = (Internal length × width × height in inches) ÷ 1,728. Multiply by bulk density (lb/ft³) to estimate payload weight. Apply a 10% buffer to prevent bulging and to comply with safety factors.
| Common size (L×W×H) | Volume (ft³) | Typical configuration | 53 ft trailer capacity* |
|---|---|---|---|
| 48×40×36 | 40.0 ft³ | Standard poly liner | 30 per 53 ft (single stack) |
| 48×40×40 | 44.4 ft³ | Tri-wall + slip sheet | 26-28 per 53 ft |
| 48×45×50 | 62.5 ft³ | Quad-wall, export grade | 20-22 per 53 ft |
| 48×40×36 (octagonal) | 38.5 ft³ | Liquid liner / fitment | 24 per 53 ft (pump-out) |
*Assumes 48×40 pallets, single stacking, and 102 in. trailer width.
Select the Right Wall Rating
| Wall rating | Bursting strength | Safe working load | Best suited for |
|---|---|---|---|
| Single wall | 200-275# | ≤ 1,000 lb | Plastic scrap, light loose product |
| Double wall | 350-500# | 1,500-2,000 lb | Mixed recyclables, plastic pellets |
| Triple wall | 600-700# | 2,500-3,000 lb | Metal components, dense resins, food ingredients |
Stacking & Warehouse Guidelines
- •Limit triple-wall gaylords to two-high stacking unless using interlocking pallets.
- •Use corner posts or banding for 50+ inch tall gaylords to prevent bulging.
- •Maintain ≥ 4 inches clearance between top layer and sprinkler heads.
- •Rotate inventory FIFO to avoid humidity-related wall degradation.
Truckload Planning Checklist
- •Model payload weight vs. trailer max gross (typically 44,500 lb freight limit).
- •For loose product, apply 10% headspace to prevent overflow during transport.
- •Use slip sheets or plastic pallets for export loads requiring ISPM-15 compliance.
- •Balance heavy and light gaylords across trailer axles to stay under DOT limits.
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