Rectangular corrugated gaylords

Material

Corrugated fiberboard, usually double or triple wall

Common footprint

48 x 40 in, matched to a standard pallet

Walls

2 to 5 layers of corrugated board

Capacity, 3-wall

Sellers cite 1,000 to 1,600 lb

What it is

A bulk box is also called a bulk bin, skid box, pallet box, bin box, gaylord or octabin, and it is usually double-wall or triple-wall corrugated fiberboard. The rectangular one is the base case. It is cut and scored, assembled from a tray and a sleeve or from a die-cut blank with a bottom, and sized to a pallet. Most of what we list is this box.

The common footprint is 48 x 40 in, matched to a standard pallet. Heights run from 24 to 50 in. Footprints of 48 x 48 and 48 x 45 in are also typical. Wall counts run from 2 to 5 layers, and the capacity sellers cite rises with the count.

Capacity by wall count

Those are ranges that sellers cite, not guarantees. Individual wall thickness varies, so wall count alone is not always reliable. The maker's rated capacity for a given box is what counts, and it is printed on the box. See reading the maker's stamp.

Choosing the bottom

A full flap bottom has flaps that overlap into a solid base. Choose it for dense parts, small pieces and powders. Full-flap gaylords typically support 1,100 to 2,500 lb depending on wall construction.

A partial flap bottom has flaps that meet in the middle without overlapping, so the box rests on a slip sheet or a solid pallet. It is common for resin and produce. For castings and small dense parts, ask for the full flap. The bottom styles guide goes further.

Where used rectangular gaylords go

• Auto suppliers covering a returnable shortage on a 48 x 45 in or 48 x 40 in footprint. See backup packs.
• Machine shops shipping gears and castings in 4- and 5-wall boxes with a full flap bottom. See defense and heavy parts.
• Warehouses and 3PLs using single-trip boxes for returns and internal moves. See warehouses and 3PLs.

Facts and figures

• Typical gaylord footprints are 48 x 40, 48 x 48 or 48 x 45 inches, with sidewalls usually 24 to 50 inches high. (nelsoncompany.com, retrieved 2026-11-10.)
• 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.)

Terms

• gaylord: A pallet-size bulk box; originally a trade name of the Gaylord Container company, now the generic word.
• die-cut: Cut and scored in one press pass; most gaylords are die-cut and assembled from a tray plus a sleeve.
• sleeve: The four side walls of a gaylord made as one tube, set into a tray bottom.
• full flap bottom: Bottom flaps that overlap to make a complete base; best for heavy loads, powders and small parts.

Choosing a rectangle over an octagon

A rectangle stacks square and fills a trailer without gaps, which is why parts, cartons and scrap use it. An octagon resists bulging under loose or flowable loads, so choose by what the box will hold.