Pallet Stack Height Calculator
Maximum safe stack height for 5-wall Gaylord boxes given filled box weight, box condition, and bottom construction. Applies the column-load rule (stack height × filled weight ≤ 3,000 lb) plus physical trailer-height constraints.
By load rule
2 high
stack × weight ≤ 3,000 lb
By trailer height
2 high
110″ interior trailer
Recommended
2 high
limiting factor
How this works
- Load rule: each column of stacked boxes carries the weight of every box above it. Standard 5-wall full flap bottom is rated to 3,000 lb static column load — so total stack weight (height × filled weight per box) shouldn't exceed it.
- Used derate: structurally inspected used boxes haven't lost the construction, but cycle-age reduces practical capacity by roughly 20-30%. We apply 25%.
- Partial flap derate: partial flap bottom has a single-layer base that flexes under high column loads. Practical capacity ~2,000 lb vs 3,000 lb for full flap.
- Trailer height: standard 53-ft dry vans have ~110 in interior height. Each level needs box height + ~5 in for the GMA pallet.
- Hard cap: even when math allows more, real warehouse handling rarely exceeds 3-high stacking.