Articles & guides

Six pieces, no gates

Practical guides to the vocabulary and decisions behind bulk packaging: what a gaylord is, how grading works, sizing, strength, liners and selling empties.

FundamentalsBuying GuideSizingTechnicalSelling Guide
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The reference sheets

Assembled triple-wall gaylord boxes on wooden pallets inside a warehouseTriple wall
Assembled triple-wall gaylords on 48×40 pallets, staged indoors.
Warehouse aisles filled with banded pallets of knocked-down corrugated bulk boxesBundles
Banded bundles of knocked-down containers sorted by footprint and height.
Knocked-down gaylord boxes banded onto pallets and loaded inside a trailerFreight
Knocked-down gaylords, banded and floor-loaded in a dry van.
Construction, thickness and typical working capacity
ConstructionThicknessTypical max weightStackingTypical use
Single wall C5/32" (4.0 mm)65 lbNot for bulkLids, layer pads, dividers
Double wall BC9/32" (7.1 mm)900 – 1,200 lb1 high loadedGeneral bulk under 1,200 lb
Double wall CC5/16" (7.9 mm)1,000 – 1,300 lb1 high loadedSlightly better cushioning than BC
Triple wall BCC7/16" (11.1 mm)2,200 – 2,500 lb2 high loadedThe bulk workhorse
Triple wall ACC1/2" (12.7 mm)2,400 – 2,700 lb2 high loadedDense product with cushioning need
Five wall AAC5/8" (15.9 mm)3,000 lb+3 high, matched palletsCastings, stampings, export
Quick conversions for bulk packaging
MeasureImperialMetricNotes
Standard footprint48 × 40 in1,219 × 1,016 mmThe GMA pallet that standardised US distribution.
Triple wall thickness7/16 in11.1 mmTakes about 7/8 in off interior width across both walls.
Typical capacity2,200 lb998 kgTriple wall BCC, evenly distributed, matched pallet.
Container cube at 36"33.3 ft³0.943 m³Outside dimensions, before board thickness.
OCC bale1,000 – 1,400 lb454 – 635 kgTypical bale from a horizontal baler.
Trailer capacity, knocked down400 – 600 units—53-foot dry van; cube limited, never weight limited.
Moisture ceiling for OCC12%12%Above this you are selling water at a penalty.
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FAQ

Questions about the articles

What topics do the Gaylord Boxes articles cover?
What a gaylord box is, how used units are graded, how sizing works, stacking strength, liner selection and selling your empties.
How many articles are there?
Six long-form pieces, each with a reading time shown on its card. More posts on operations and freight live on the blog.
Are the articles gated?
No. Every article is free to read without an email address, and each one links to the related references and the quote form.
What is the difference between the articles and the blog?
Articles are the core reference guides on fundamentals. The blog holds longer posts on freight, operations, market seasonality and common failures.
Can I ask for an article on a specific topic?
Yes. Use the form on this page to suggest a topic.