- Walls
- 4 layers of corrugated
- Capacity sellers cite
- 1,500 to 2,200 lb
- Heights cited
- 36 to 41 in
- Common footprint
- 48 x 40 in
What 4-wall carries
Container Exchanger gives common gaylord heights of 36 to 41 in for a 4-wall box, and sellers cite 1,500 to 2,200 lb. It overlaps with the top of triple wall and the bottom of five-wall. That overlap is where the maker's stamp matters most, because two boxes sold as 4-wall can differ by hundreds of pounds.
Full-flap bottom gaylords typically support 1,100 to 2,500 lb depending on wall construction. A 4-wall with a full flap bottom is a good fit for machined parts, gears and small castings, a few dozen boxes at a time.
Choosing 4-wall over its neighbors
| Choice | Cited capacity | Pick it when |
|---|---|---|
| 3-wall | 1,000 to 1,600 lb | The loaded box is comfortably under 1,500 lb |
| 4-wall | 1,500 to 2,200 lb | The load is 1,500 to 2,000 lb, or the lane is rough |
| 5-wall | 2,000 to 3,000 lb | The load is dense and near 2,500 lb or more |
If the finder or your own arithmetic puts you near an edge, move up one count. The cost of the next wall is small next to a bottom that lets go on a dock. Then ask for a full flap bottom, and for a liner if the parts are oily. See heavy-duty gaylords for defense parts.
Sizes that suit 4-wall
The sizes in our catalogue that sit inside the 36 to 41 in heights makers cite for 4-wall:
- 48 x 40 x 36 in: 40 cu ft, 1,500 lb in one distributor's listing (triple wall)
- 48 x 45 x 40 in: 50 cu ft
- 48 x 48 x 36 in: 48 cu ft, 1,400 lb in one distributor's listing (triple wall)
- 40 x 40 x 40 in: 37 cu ft, 1,300 lb in one distributor's listing (triple wall)
- 36 x 36 x 36 in: 27 cu ft, 1,200 lb in one distributor's listing (triple wall)
- 46 x 38 x 36 in octagon: octagon, 1,300 lb in one distributor's listing (triple wall)
Boxes needed to move a given weight in 4-wall
| Total weight (lb) | Boxes at 1,500 lb | Boxes at 2,200 lb | Boxes at 70% of the low figure |
|---|---|---|---|
| 5,000 | 4 | 3 | 5 |
| 10,000 | 7 | 5 | 10 |
| 15,000 | 10 | 7 | 15 |
| 20,000 | 14 | 10 | 20 |
| 30,000 | 20 | 14 | 29 |
| 40,000 | 27 | 19 | 39 |
| 45,000 | 30 | 21 | 43 |
Facts and figures
- Container Exchanger gives common gaylord heights of 30-36 in for 2-wall, 34-40 in for 3-wall, 36-41 in for 4-wall and 36-46 in for 5-wall boxes. (blog.containerexchanger.com, retrieved 2026-11-10.)
- Gaylord boxes range from 2 to 5 layers of cardboard, and many are sized for 40 x 48 or 45 x 45 inch pallets. (blog.containerexchanger.com, retrieved 2026-11-10.)
Terms
- wall count: How many layers of corrugated board form the side walls, from 2 to 5; more walls, more stacking strength.
- full flap bottom: Bottom flaps that overlap to make a complete base; best for heavy loads, powders and small parts.
- ECT: Edge crush test, a rating of how much top load a board's edge carries; a stacking-strength number.
- Container Exchanger, the gaylord box guide
- The Cary Company, gaylord boxes: history and handling
- Uline, triple-wall boxes (1,100 lb test)