Three bottoms
| Bottom | How it is built | Good for | Watch for |
|---|---|---|---|
| Full flap | Flaps overlap to make a complete base | Dense parts, powders, small pieces, castings | A little heavier; flaps must be intact |
| Partial flap | Flaps meet in the middle without overlapping | Resin, produce, light parts | Needs a slip sheet or a solid pallet |
| Sleeve and tray | A separate base tray and a sleeve | Return trips; flat storage | Joint between tray and sleeve |
Why it matters
Everything in a gaylord ends up on its bottom. A wall can be sound and the box still fail because the bottom does. Full-flap bottom gaylords typically support 1,100 to 2,500 lb depending on wall construction. A partial flap leaves a gap where the flaps do not overlap, so the load rests on whatever is under the box. If that is a solid pallet or a slip sheet, it works. If it is a slatted pallet with nothing on it, small parts fall through.
The rule of thumb on the dock is simple. Dense, small or sharp: full flap. Flowable and light enough: partial flap with a slip sheet is fine. Coming back: sleeve and tray. See slip sheets for the details of the middle one.
Used bottoms
- Press the bottom for damp. Soft means a lower grade.
- Look for crushed flap folds. A flap that has lost its crease no longer overlaps.
- Look for punctures from pallet nails.
- Check that tape or staples on the bottom are sound.
Ask for it by name
The form asks for the bottom style: full flap bottom, partial flap bottom, sleeve and tray, or not sure. Say not sure if you are not. We ask a question or two and settle it. For castings, the answer is full flap, and for resin or produce on a slip sheet it is partial. See the catalogue and sleeve and tray.
| Walls | Low (lb) | High (lb) | Low height (in) | High height (in) |
|---|---|---|---|---|
| 2-wall | 800 | 1,200 | 30 | 36 |
| 3-wall | 1,000 | 1,600 | 34 | 40 |
| 4-wall | 1,500 | 2,200 | 36 | 41 |
| 5-wall | 2,000 | 3,000 | 36 | 46 |
Facts and figures
- Virginia Tech research found effective box compression strength decreases as pallet overhang increases, with overhang magnitude, box perimeter and board type the significant predictors. (vtechworks.lib.vt.edu, retrieved 2026-11-11.)
Terms
- full flap bottom: Bottom flaps that overlap to make a complete base; best for heavy loads, powders and small parts.
- partial flap bottom: Bottom flaps that reach the middle without overlapping, so the box rests on a slip sheet or pallet; common for resin and produce.
- slip sheet: A thin solid-fiber sheet laid under a partial-bottom box to close the base and keep pallet nails off the load.
- tray bottom: A shallow corrugated base that a sleeve sits in.
- Wikipedia, bulk box
- Container Exchanger, the gaylord box guide
- Container Exchanger, new and used gaylord boxes