48 × 40 × 36 in 5-Wall Gaylord Box
A 48 × 40 × 36 in 5-wall Gaylord is a 40 ft³ bulk container on a GMA pallet footprint, rated to 3,000 lb static load (TAPPI T 811 ECT 32+, T 810 burst ~600 psi). The most-ordered size in industrial bulk shipping.
Specifications
All structural ratings reference TAPPI T 811 (ECT), TAPPI T 810 (Mullen burst), and the GMA 48 × 40 in pallet standard.
| Outside dimensions | 48 × 40 × 36 in (48″L × 40″W × 36″H) |
| Interior dimensions | ~47.5″ × 39.5″ × 35.5″ (5-wall thickness ≈ 0.5″/side) |
| Interior volume | 40.0 ft³ · 1.133 m³ · 1,133 L · 299 US gal |
| Empty weight | ~28 lb (varies by liner basis weight) |
| Static load rating | Up to 3,000 lb (column-stacked, new condition) |
| Edge Crush Test (ECT) | 32+ ECT (TAPPI T 811) |
| Burst test (Mullen) | ~600 psi (TAPPI T 810) |
| Construction | 5-wall: 3 kraft liners + 2 corrugated mediums (BC double-wall) |
| Liner basis weight | 33-42 lb/Msf kraft (HTP-41 available) |
| Pallet match | Standard 48 × 40 in GMA pallet |
| Stack tier | standard format (36 in height) |
| 53-ft trailer capacity | ~30 boxes single-stacked, ~60 double-stacked |
48×40×36 calculator
Box count for a given product volume, pallet stack height for a given fill weight, and trailer load count.
Enter the total volume of product you need to ship. We'll estimate the box count assuming a typical 85% fill rate (real loads rarely pack to 100% of interior volume).
Boxes needed
30
of 48 × 40 × 36 in (≈ 85% fill)
Estimates only. Real freight planning depends on actual product density, pallet build, dunnage, and carrier equipment.
48×40×36 vs other 48 × 40 in heights
All sizes share the GMA pallet footprint; only the height changes.
| Size | Volume (ft³) | Liters | Trailer (single) | Trailer (double) |
|---|---|---|---|---|
| 48 × 40 × 24 in | 26.7 | 756 | ~30 | ~60 |
| 48 × 40 × 28 in | 31.1 | 881 | ~30 | ~60 |
| 48 × 40 × 30 in | 33.3 | 945 | ~30 | ~60 |
| 48 × 40 × 36 in | 40.0 | 1,133 | ~30 | ~60 |
| 48 × 40 × 40 in | 44.4 | 1,258 | ~26 | ~52 |
| 48 × 40 × 42 in | 46.7 | 1,322 | ~26 | ~52 |
| 48 × 40 × 45 in | 50.0 | 1,416 | ~26 | — |
| 48 × 40 × 48 in | 53.3 | 1,510 | ~26 | — |
5-wall 48×40×36 vs tri-wall and IBC
The two closest alternatives to a 5-wall corrugated Gaylord for industrial bulk shipping.
| Attribute | 5-wall 48×40×36 | Tri-wall 48×40×36 | Plastic IBC (275-330 gal) |
|---|---|---|---|
| Static load rating | Up to 3,000 lb | Up to 1,500 lb | Up to 2,000 lb (liquid) |
| ECT (TAPPI T 811) | 32+ | ~24 | N/A (rigid plastic) |
| Empty weight | ~28 lb | ~20 lb | ~120-150 lb (with cage) |
| Interior volume | 40.0 ft³ | 40.0 ft³ (same nominal) | ~37-44 ft³ (275-330 gal) |
| Cost tier | Mid (corrugated) | Lower | Highest (rigid plastic) |
| Reuse cycles (typical) | 5-8 (standard), 12-20 (HTP-41) | 2-4 | 25+ (with reconditioning) |
| Recyclable end-of-life | Yes — OCC fiber | Yes — OCC fiber | HDPE recovery (varies regionally) |
| Best for | Dry / solid bulk industrial | Light dry, one-way ship | Liquids and viscous bulk |
48 × 40 × 36 in 5-wall Gaylord FAQs
What are the interior dimensions of a 48 × 40 × 36 in Gaylord box?
Approximately 47.5 × 39.5 × 35.5 in interior. Usable interior volume is roughly 38.5 cubic feet at theoretical full fill.
How much does an empty 48 × 40 × 36 in 5-wall Gaylord weigh?
Approximately 26-32 lb empty depending on liner basis weight (33-42 lb/Msf is standard kraft). HTP-41 builds run 34-40 lb.
What is the maximum load weight for a 48 × 40 × 36 in Gaylord?
Up to 3,000 lb static load when new, properly stacked on a flat pallet with even weight distribution. The rating applies to the standard 5-wall construction at 32+ ECT (TAPPI T 811).
Why is 48 × 40 × 36 the most popular Gaylord size?
It matches the largest interior volume that still fits cleanly into most standard warehouse racking, forklift mast heights, and trailer load plans. The 40 ft³ interior also covers the middle of nearly every industrial product-density curve without burning excess cube or hitting weight caps prematurely.
How many 48 × 40 × 36 boxes fit on a 53-foot trailer?
About 30 single-stacked or 60 double-stacked. A standard 53-ft dry van holds 26 GMA pallet positions plus 4 spillover; one box per position single-stack, two per position double-stack.
Can I stack 48 × 40 × 36 Gaylords 2- or 3-high on the warehouse floor?
Yes for two-high with full flap bottom construction under the column rule (stack × filled weight ≤ 3,000 lb). Three-high is feasible only at lighter fill weights (~1,000 lb per box or under). Used boxes derate 20-30%.
Are 48 × 40 × 36 Gaylord boxes food-grade?
The corrugated box itself is not a food-contact surface. For bulk food applications, pair the new virgin-kraft Gaylord with an FDA-compliant PE liner per 21 CFR 177.1520 (typically 3 mil for dry powders, 5-6 mil for IQF frozen or wet product).
What's the difference between 48 × 40 × 36 and 48 × 40 × 45 sizes?
Both share the GMA pallet footprint. The 36 in holds 40 ft³; the 45 in holds 50 ft³ (25% more cube). The 36 in still allows double-stacking in standard trailers; the 45 in is typically single-stack. Use 45 in for light, bulky product where freight cost is cube-governed.
Can I get printed or custom-color 48 × 40 × 36 boxes?
Yes — single- and multi-color flexo print is available on new orders. Lead times run 2-3 weeks longer than stock. Minimum order quantities apply.
Are 48 × 40 × 36 in Gaylord boxes available in used or scrap condition?
Yes. Used inspected condition offers 40-70% savings over new and is the most-rotated size in our used inventory. Scrap condition is sold for OCC fiber recovery only.
What's the lead time for 48 × 40 × 36 in Gaylords?
Stock orders ship within 2-5 business days. Custom prints, non-standard board grades, or food-grade liner orders add 2-3 weeks.
Are 48 × 40 × 36 in Gaylord boxes recyclable?
Yes — they're 100% old corrugated container (OCC) grade kraft fiber and are accepted by every US paper mill that buys recycled corrugated. End-of-life boxes sold for fiber recovery go through our scrap channel.
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