Gaylord boxes are among the most valuable types of shipping containers. They come in different sizes and standards, each with varying weight capacities. Because of their durable construction, businesses can reuse them safely multiple times, reducing shipping costs and waste.
Before we cover how much a Gaylord box weighs, consider these other facts about Gaylord Boxes:
- There are multiple kinds and standards of Gaylord boxes.
- The maximum weight of a Gaylord box depends on the dimensions, construction and corrugated fiberboard wall thickness.
- The heavier the walls, the higher the tensile strength and resistance to rough handling, and the more expensive they are.
What Is a Gaylord Box?
The term Gaylord box refers to bulk cargo boxes intended to fit on pallets. To comply with the Gaylord definition, a box must be large, made from robust corrugated cardboard and engineered explicitly for bulk storage and easy palletization.
Gaylord boxes are either rectangular or octagonal and come in multiple standard dimensions and designs, with the five most common being the Standard Gaylord, D, Mini D, E and EH.
The Standard Gaylord Box
Standard Gaylord boxes feature dimensions of 48” x 40” x 36”. These dimensions are ideal for stacking and palletization, making this type of Gaylord box easy to store in warehouses and to ship. Typically, at least 450 of these boxes can fit in a standard semi-trailer, although the exact number depends on the boxes’ wall thickness and palletization methods employed.
Standard Gaylord boxes are usually rectangular, featuring two parts: a bottom and a lid. Both elements employ the same type of heavy-duty corrugated cardboard. Their strength depends on the number of walls, which may vary significantly, from single-walled to five-walled models.
Some Gaylord boxes may feature an octagonal shape with a matching lid instead of standard rectangular dimensions. Octagonal boxes are often more expensive but provide additional strength and better weight distribution.
To ensure your products are safe, it’s essential you use the correct version of a corrugated Gaylord container. It’s helpful to know the maximum weight capacity of the five main options:
- Single-wall: These boxes feature only a single layer of corrugated cardboard material. They may only support up to 65 to 95 lbs., depending on the cardboard grade employed.
- Double-wall: Double-walled Gaylord boxes support between 95 and 120 lbs., depending on the cardboard grade employed.
- Triple-wall: Triple-layer Gaylord boxes usually possess a maximum cargo capacity of 120 to 280 lbs. Some extra-strength cardboard grades—e.g., ECT-155—may support up to 300 lbs.
- Quadruple-wall: This type of Gaylord box is also known as a four-wall or four-ply box. As an industrial-grade container, this type of Gaylord box often features a bottom reinforced with a wood pallet, allowing easy transportation and moving in a warehouse. The maximum capacity of four-wall Gaylord boxes varies between 2,000 and 2,500 lbs.
- Five-wall: Five-wall Gaylord boxes are exceptionally strong and highly resistant to abuse and rough handling. Like four-wall models, five-wall Gaylord boxes often possess reinforced pallet bottoms. Their exceptional strength allows for a maximum capacity of up to 4,000 to 5,000 lbs.
D and Mini D Containers
A “D” container is a type of four-piece Gaylord box. Standard dimensions are 58” x 42” x 45”, although some models may feature slightly different heights, lengths, and depths.
The four-piece design consists of a bottom piece, a three-walled, open-ended body, a separate fourth wall and a lid. This design provides you with an extra-strength, bursting-resistant container that requires no glue, nails or staples to assemble. Simply insert the pieces in the correct order, and your D container is ready to use.
Most D containers feature heavy-duty fiberboard materials with double-wall thickness. This box type possesses a maximum weight capacity of about 1,200 lbs.
Some D containers possess a reinforced bottom with a wood pallet, similar to reinforced standard Gaylord boxes. The integrated pallet bottom makes transportation and palletization convenient.
There are also “Mini D” containers available, which have smaller dimensions—48” x 40” x 40”—but otherwise identical strength and maximum capacity. These containers are excellent for shipping smaller, denser objects, such as mechanical parts or small motors.
E and EH Containers
An “E” container is, essentially, a large corrugated fiberboard box. Although an E container resembles regular cardboard boxes, it has big enough dimensions—42” x 29” x 26”—for bulk storage and shipping.
“E” containers may either feature a lid or the four traditional slots, depending on the design and manufacturing process. They typically employ the same materials as D containers: heavy-duty, double-wall fiberboard, providing a maximum weight capacity of about 600 lbs.
“EH” containers are a variant of E containers featuring smaller dimensions. Typical EH containers are 36” x 22” x 22” and have a similar weight capacity. If you need to ship denser objects, like tools or metal elements, you may benefit from the EH container’s smaller size.
Use the Right Boxes for Your Shipping Business
The maximum weight capacity of a Gaylord container does not depend solely on the dimensions but also the material thickness, measured in the number of walls.
The more walls a cardboard container possesses, the more corrugated fiberboard layers it comprises, increasing the overall tensile strength, resistance to rough abuse and handling and maximum weight capacity.
The exceptional resistance of a Gaylord container also contributes to their reusability, making them valuable. If handled properly and carefully, you can reuse a single Gaylord container dozens of times.
Air Sea Containers offers a selection of high-quality Gaylord boxes and other bulk cargo containers in various dimensions and standards, such as D, Mini D, E, EH and more. We also provide a large selection of packaging materials, signage and documentation for shipping professionals worldwide.