The method
This page does arithmetic. It is not a quote and not a load plan. We use round working numbers for the trailer: 636 in long, 100 in wide and 108 in high inside, and a 6 in pallet under every box. Inside dimensions vary by trailer, so check the one your carrier sends.
For each box, try both orientations. Along the floor, divide the trailer length by the box side that runs lengthwise and round down to get rows. Across, divide the width by the other side and round down. Multiply rows by boxes across for the floor count. Then divide the height by the box height plus the pallet and round down for layers.
All eleven sizes
| Size | Rows x across = floor | Layers that fit | Ceiling |
|---|---|---|---|
| 48 x 40 x 36 in | 15 x 2 = 30 | 2 (42 in a layer) | 60 |
| 48 x 45 x 40 in | 14 x 2 = 28 | 2 (46 in a layer) | 56 |
| 48 x 40 x 24 in | 15 x 2 = 30 | 3 (30 in a layer) | 90 |
| 48 x 40 x 48 in | 15 x 2 = 30 | 2 (54 in a layer) | 60 |
| 48 x 48 x 36 in | 13 x 2 = 26 | 2 (42 in a layer) | 52 |
| 48 x 48 x 48 in | 13 x 2 = 26 | 2 (54 in a layer) | 52 |
| 40 x 40 x 40 in | 15 x 2 = 30 | 2 (46 in a layer) | 60 |
| 36 x 36 x 36 in | 17 x 2 = 34 | 2 (42 in a layer) | 68 |
| 40 x 30 x 30 in | 15 x 3 = 45 | 3 (36 in a layer) | 135 |
| 48 x 24 x 28 in | 13 x 4 = 52 | 3 (34 in a layer) | 156 |
| 46 x 38 x 36 in octabin | 16 x 2 = 32 | 2 (42 in a layer) | 64 |
Why the last column is a ceiling
- Box rating. The lower box carries the upper. Damp air can cut a box's compression strength by about half, so a stack that is safe in a dry building may not be in a wet trailer.
- Overhang. Effective box compression strength decreases as pallet overhang increases, so a box should not hang over its pallet.
- Weight. A trailer has a weight limit as well as a floor, and dense loads reach it first. Heavy parts mean fewer boxes.
- Carrier rules. Some carriers will not stack gaylords, or set their own limits.
For a load plan, use your carrier's trailer dimensions and your loaded box weights. Send them with a request and we check the box.
Related: the 48 x 40 x 36 in page, gaylord sizes, and weight capacity.
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.)
- 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
- pallet footprint: The box's length and width matched to a pallet, most often 48 x 40 in.
- standard pack quantity: How many parts go in one container under the customer's packaging spec.