Charlotte region, NC and SC I-85 I-77 I-40
How many knocked-down gaylords fit on a pallet comes down to one measurement: how thick one flattened box is. Divide the height you can stack by that thickness. This page shows the arithmetic and what to check before you band a stack.
A set-up gaylord is a big, hollow box. A knocked-down gaylord is flat, and it has a thickness: the board of the walls and bottom folded down. That thickness depends on the wall count, because each wall has its own layers, and on how the flaps were folded. Measure one flat box with a tape and write it down.
As an example only, if one flat box measures 3 inches thick and you can stack 60 inches above the pallet, you get 20 boxes. A box twice as thick gives half the number. Use your measured thickness.
| Wall count | What changes | Effect on the count |
|---|---|---|
| 2‑wall | Thinner board | More per pallet |
| 3‑wall | Medium | Middle |
| 4‑wall | Thicker | Fewer |
| 5‑wall | Thickest | Fewest |
Align the edges, put the biggest panels down, and band the stack in two directions. A flat stack that leans can tumble in a truck. Wrap the top and sides if it will wait outside. Keep it off the floor on a pallet.
A flat stack takes the footprint of the box. A 48 x 40 stack sits on a 48 x 40 pallet. A 48 x 48 stack on a 48 x 40 pallet overhangs, and Virginia Tech research found effective box compression strength decreases as pallet overhang increases (source). Fit the footprint to the pallet where you can.
Do not mix footprints on one pallet. Group by footprint and wall count, so the count on each pallet is easy to read. A tag on each pallet with the number and the footprint saves a recount at the dock.
How many pallets fit on a truck follows the per-truck guide. How to fold and keep the boxes dry is on the folding and storing guide.
Put the number of pallets, the footprint, the count per pallet and the condition in the request. We read it and say what fits.
Strap a stack across its middle with bands set a hand's width in from each corner, so the bands do not crush the board. Keep the flat stack off the floor on a pallet, cover the top, and never leave it where the lowest sheet can wick up moisture. Count the sheets, not the pallets, in your request, and say how many sheets sit in each stack. A stack that has been flat for a long time can curl, and a few lines about how long it has been stored will help a buyer plan.
Set up, one box per pallet. Knocked down, divide your stack height by the thickness of one flat box.
Measure one flat box and divide the stack height by it. A thinner board means more boxes.
Yes, in two directions, with the edges aligned. It keeps the stack stable and the corners from crushing.
Count, footprint and wall count are enough to start.
No prices, minimums or times are stated here.