Charlotte region, NC and SC I-85 I-77 I-40
I-85I-77
Wall count is the number of layers of corrugated board in the side walls, from 2 to 5. More layers carry more load and stack higher, but the maker rating for the exact box is the number to trust, not the count alone.
The first thing a buyer asks about a used gaylord is how many walls it has. The second is how many pounds it carries. They are linked but not the same question. Wall count tells you how much board there is. Capacity depends on the board's grade, the box's height, how the bottom is closed and whether the load is stacked.
| Wall count | Capacity sellers cite | Common heights | Suits |
|---|---|---|---|
| 2‑wall | 800 to 1,200 lb | 30 to 36 in | Light freight on the floor |
| 3‑wall (triple wall) | 1,000 to 1,600 lb | 34 to 40 in | General parts and scrap |
| 4‑wall | 1,500 to 2,200 lb | 36 to 41 in | Dense loads, stacking |
| 5‑wall | 2,000 to 3,000 lb | 36 to 46 in | Heavy parts, resin, long storage |
The capacity ranges come from sellers (Container Exchanger). They are not guarantees and they are not a maker's rating.
The Cary Company lists gaylords in single wall 200#/ECT-32, double wall 275#/ECT-48 and triple wall 1100#/ECT-90 across sizes from 36 x 36 x 36 to 48 x 40 x 36 (source). Uline rates its triple-wall 48 x 40 x 36 gaylord at 1,500 lb and its 36 x 36 x 36 at 1,200 lb (source). Those two sizes show how footprint and height change the figure for the same wall count. The 48 x 40 x 36 page works through the first one.
Individual wall thickness varies, so wall count alone is not always reliable. Two 3‑wall boxes from different makers can carry different loads. When a listing gives an ECT or a pound-test, use it. When it does not, ask for it before you stack anything.
Corrugated boxes lose about half of their compression strength when relative humidity rises from 50 to 90 percent (source), and stacked boxes in humid storage may lose nearly 45 percent after 90 days (source). So a used 4‑wall box that spent months in a damp yard is no longer a 4‑wall box in practice. See the grading guide.
The weight capacity guide walks the steps. The size board lists capacity for standard sizes.
Choose the wall count in the form or choose not sure. If you are buying for a heavy part, add the part's weight and how many go in a box.
Full-flap bottom gaylords typically support 1,100 to 2,500 lb depending on wall construction (source). That range overlaps the 3‑wall and 4‑wall ranges above because the bottom is part of what holds the load. A 3‑wall box with a closed bottom can carry more than the same box with an open one, which is why the bottom is the second question after the wall count.
Container Exchanger gives common heights of 30 to 36 inches for 2‑wall boxes, 34 to 40 for 3‑wall, 36 to 41 for 4‑wall and 36 to 46 for 5‑wall (source). A box of the wrong height for its wall count is worth a second look, since it may have been cut down or built to a different spec.
A stamp may give a burst test in pounds, such as 275#, or an edge crush test, such as ECT-48, or both. The burst test is the older way of rating board; edge crush is the stacking-strength number. A seller who reads both off the stamp has done most of the work a buyer will ask for.
Look at the cut edge of the sidewall. Each wall is a sandwich of two flat liners and a wavy fluted medium between them. Count the fluted layers: two layers is a double wall, three is a triple wall. A two-wall gaylord is the lightweight choice for dry, light loads. A five-wall box is the heaviest and is built for dense loads such as castings and fasteners. If the edge is covered in tape, check the flap, where the cut face is exposed.
Two boxes with the same wall count can differ in strength if the board grade differs. The edge crush rating on the stamp is the number that settles it. When there is no stamp, the wall count and the height are the next best evidence, and you can state both in the request.
Start from the weight of what goes in one box, then leave room. A box of light, bulky material such as film or textile scrap is limited by volume and will usually be happy in two or three walls. A box of dense metal parts is limited by weight and wants four or five. Mixed loads follow the heaviest item. If you cannot weigh a loaded box, weigh one part and multiply, then add the weight of any dividers.
It is the number of layers of corrugated board in the side walls, from 2 to 5. It is the first thing a buyer asks because it drives stacking strength.
Usually, but the board grade and the build matter too. Compare maker ratings rather than counts alone.
Three layers of corrugated board, shortened to TW. It is the standard heavy gaylord and the most common box in a plant's inbound stack.
Count, footprint and wall count are enough to start.
No prices, minimums or times are stated here.