5-Gallon Pail Load Capacity & Stacking 2026

5-Gallon Pail Load Capacity & Stacking Guide

Published: February 11, 2026 | PailHQ Technical Team | 8 min read

Proper stacking and load management are critical for warehouse safety, shipping compliance, and product integrity. Whether you're palletizing 36 pails for a regional shipment or managing 10,000+ units in a distribution center, understanding load capacity limits and stacking best practices prevents costly damage and regulatory violations.

This guide covers everything you need to know about 5-gallon pail load capacity, stacking limits, pallet configurations, and DOT/OSHA compliance for warehouse storage.

5-Gallon Pail Capacity Specifications

Before calculating stacking loads, you need to know the baseline weight specifications for standard 5-gallon HDPE pails.

Weight Specifications

| Specification | Value |

|---|---|

| Empty pail weight | 1.8-2.2 lbs (0.8-1.0 kg) |

| Nominal capacity | 5.0 US gallons (18.9 liters) |

| Actual fill capacity | 5.28 US gallons (20.0 liters) with headspace |

| Filled weight (water) | ~42 lbs (19.1 kg) |

| Filled weight (paint, latex) | ~55-60 lbs (25-27 kg) |

| Filled weight (sand/aggregate) | ~65-70 lbs (29-32 kg) |

| Lid weight (snap-on) | 0.3-0.5 lbs |

| Lid weight (gasket) | 0.5-0.8 lbs |

Dimensional Specifications

| Dimension | Value |

|---|---|

| Height (with lid) | 14.5 inches (368 mm) |

| Top diameter | 12.0 inches (305 mm) |

| Bottom diameter | 10.5 inches (267 mm) |

| Wall thickness | 70-90 mil (1.8-2.3 mm) |

The tapered design (wider at top, narrower at bottom) is intentional — it allows empty pails to nest inside each other for efficient storage and enables interlocking when stacked with lids.

Load Capacity by Material

Not all 5-gallon pails have the same load-bearing capacity. Material grade, wall thickness, and manufacturing process all affect how much weight a pail can safely support.

HDPE Load Ratings

|---|---|---|---|

| 70 mil (standard) | 50 lbs | 120 lbs | 2-3 layers filled |

| 80 mil (heavy duty) | 55 lbs | 150 lbs | 3 layers filled |

| 90 mil (industrial) | 60+ lbs | 180 lbs | 3-4 layers filled |

Top-load capacity refers to the maximum weight that can be placed on top of a single sealed pail without causing permanent deformation. This is the critical number for determining safe stacking height.

Factors That Reduce Load Capacity

Elevated temperature: Load capacity decreases approximately 10% for every 20°F above 75°F
UV exposure: Prolonged sun exposure degrades HDPE, reducing structural integrity over months
Chemical contents: Some chemicals (surfactants, solvents) can cause environmental stress cracking that weakens walls over time
Duration of load: Static loads maintained for weeks or months cause more deformation than short-term transit loads

UN Certification Weight Ratings

For hazmat applications, UN-certified pails have specific maximum gross weight ratings that must not be exceeded.

Understanding UN Weight Codes

The UN marking 1H2/Y27/S includes the weight rating:

| Code Element | Meaning |

|---|---|

| Y | Packing Group II and III approved |

| 27 | Maximum gross mass = 27 kg (59.5 lbs) |

| S | Approved for solid contents |

Maximum gross mass includes the weight of the pail, lid, and contents combined. For a Y27-rated pail weighing 2 lbs empty with a 0.5 lb lid:

Maximum content weight = 27 kg - pail weight - lid weight
Maximum content weight = 59.5 lbs - 2.5 lbs = 57.0 lbs

Common UN Weight Ratings for 5-Gallon Pails

|---|---|---|---|

| Y18 | 18 kg (39.7 lbs) | 37 lbs | Lightweight chemicals |

| Y27 | 27 kg (59.5 lbs) | 57 lbs | Standard industrial chemicals |

| X30 | 30 kg (66.1 lbs) | 63 lbs | Packing Group I (high hazard) |

Exceeding the UN-rated gross mass voids the certification and creates DOT violations for hazmat shipments.

Stacking Limits and Guidelines

Filled Pail Stacking

|---|---|---|---|

Empty Pail Stacking

Empty pails can be stacked higher because they weigh significantly less:

| Configuration | Max Layers | Notes |

|---|---|---|

| Nested (no lids) | 8-10 | Pails nest inside each other, very stable |

| With lids (stacked) | 5 | Lids provide flat stacking surface |

| On pallet (banded) | 5 | With stretch wrap and corner boards |

The 3-Layer Rule

For most warehouse operations, 3 layers of filled pails is the practical maximum. This rule accounts for:

Long-term creep deformation of HDPE under sustained load
Temperature variations in non-climate-controlled warehouses
Forklift impact vibrations transmitted through stack
Safety margin for worker handling near stacks

Pallet Configurations

Standard pallet configurations for 5-gallon pails maximize space utilization while staying within weight limits for material handling equipment and transportation.

Standard 48" x 40" Pallet (GMA Pallet)

|---|---|---|---|---|

| Light load | 12 | 2 | 24 | ~1,008 lbs |

| Standard | 12 | 3 | 36 | ~1,512 lbs |

| Maximum | 12 | 4 | 48 | ~2,016 lbs |

| Empty pails | 36 | 3 | 108 | ~216 lbs |

Layer Arrangement

A standard 12-pail layer on a 48" x 40" pallet uses a 4x3 arrangement:

4 pails along the 48-inch side (12" diameter x 4 = 48")
3 pails along the 40-inch side (12" diameter x 3 = 36")
Overhang: 0" on the 48" side, 4" total on the 40" side (2" per side)

This configuration provides 96% pallet utilization with minimal overhang.

Extended Pallet Configurations

|---|---|---|---|

| 48" x 40" (GMA) | 12 | 3-4 | 36-48 |

| 48" x 48" | 16 | 3-4 | 48-64 |

| 48" x 42" | 12 | 3-4 | 36-48 |

DOT and OSHA Stacking Regulations

DOT (Department of Transportation)

For over-the-road transport, DOT regulations under 49 CFR impose the following requirements:

Maximum vehicle gross weight: 80,000 lbs (most states)
Load securement: Pallet loads must be secured per 49 CFR 393.100-136
Hazmat stacking: UN-certified containers must be loaded with markings visible and oriented upright
Stack test compliance: UN-certified pails must pass a 28-day stack test equivalent to 3 containers high at 104°F

OSHA (Occupational Safety and Health Administration)

OSHA's general duty clause and specific standards require:

Stable stacking: Materials must be stacked, blocked, interlocked, and limited in height to prevent sliding, falling, or collapse (29 CFR 1910.176)
Clearance: Adequate clearance must be maintained around stacks for fire protection
Weight limits: Stacked loads must not exceed the rated floor capacity
Height limits: Stacks must not interfere with sprinkler systems (minimum 18 inches clearance below sprinkler heads per NFPA 13)

Warehouse Best Practices

Temperature Management

Ideal storage temperature: 50-85°F (10-30°C)
Maximum recommended: 100°F (38°C) — above this, reduce stack height by 1 layer
Minimum recommended: 0°F (-18°C) — HDPE maintains impact resistance but handle with care
Avoid rapid temperature changes: Thermal cycling can cause seal loosening and content expansion

UV Protection

Store pails away from direct sunlight and skylights
UV-stabilized HDPE extends outdoor exposure tolerance but indoor storage is always preferred
If outdoor storage is unavoidable, cover pallets with UV-resistant tarps or shrink wrap with UV inhibitors

Floor Loading

Verify warehouse floor load capacity before stacking multiple pallets
Standard concrete slab: 250-500 lbs per square foot
A fully loaded pallet of 36 filled pails weighs approximately 1,600 lbs and occupies 13.3 square feet = 120 lbs/sq ft

Stacking Stability Factors

Interlocking Patterns

The tapered design of 5-gallon pails creates natural interlocking when stacked with lids:

Lid lip nests into the bottom ring of the pail above
Bottom ring diameter (10.5") centers on the lid surface (12" diameter)
This creates a 0.75-inch self-centering ledge on all sides

Securing Methods

| Method | Application | Cost |

|---|---|---|

| Stretch wrap (machine) | Full pallet loads, 3+ layers | $0.50-1.00/pallet |

| Stretch wrap (hand) | Partial pallets, small orders | $1.00-2.00/pallet |

| Corner boards | Heavy loads, long-distance shipping | $0.75-1.50/pallet |

| Banding (polyester) | Maximum security, export shipping | $1.50-3.00/pallet |

| Tier sheets (corrugated) | Between layers for stability | $0.50-1.00/sheet |

| Pallet caps | Top protection | $0.75-1.25/cap |

Best Practice: Wrap + Corner Boards

For most shipments, the combination of machine-applied stretch wrap (3-5 revolutions) plus corner boards provides the best cost-to-protection ratio. This method:

Prevents lateral shifting during transport
Distributes compressive load evenly across the top layer
Costs approximately $2.00-3.00 per pallet
Reduces damage claims by 85% compared to unwrapped pallets

Weight Distribution Calculations

Single Stack Calculations

To calculate the load on the bottom pail in a stack:

Bottom pail load = (Number of pails above) x (individual pail gross weight)

Example for a 3-high stack of water-filled pails:

Each filled pail = 42 lbs
Bottom pail supports = 2 x 42 lbs = 84 lbs top load
PailHQ 90-mil pails rated for 180 lbs top load = 46.7% of capacity (safe)

Full Pallet Load Calculations

For a standard pallet (12 pails/layer x 3 layers):

Total pail weight = 36 x 42 lbs = 1,512 lbs
Pallet weight = 40-50 lbs
Total pallet gross weight = approximately 1,560 lbs
Bottom layer per-pail load = (2 layers x 42 lbs) = 84 lbs per pail

Frequently Asked Questions

How many 5-gallon pails fit on a standard pallet?

A standard 48" x 40" GMA pallet holds 12 pails per layer. With 3 layers of filled pails, that's 36 pails per pallet. Empty pails can be stacked higher — up to 108 pails per pallet (36 per layer x 3 layers nested). Use our Pallet Calculator for custom configurations.

What is the maximum weight a 5-gallon HDPE pail can hold?

Standard 70-mil HDPE pails are rated for approximately 50 lbs of contents. Industrial 90-mil pails handle 60+ lbs. For UN-certified pails, the maximum gross weight (pail + lid + contents) is stamped on the pail — typically Y27, meaning 27 kg (59.5 lbs) maximum gross mass.

Can I stack filled 5-gallon pails 4 layers high?

Four layers is possible with industrial-grade 90-mil pails for short-term staging, but 3 layers is the recommended maximum for long-term warehouse storage. Factors like ambient temperature above 85°F, chemical contents, and storage duration beyond 30 days all favor keeping stacks at 3 layers or fewer.

Do I need stretch wrap for pallet shipments?

Yes. Unwrapped pallet loads of 5-gallon pails are a significant damage and liability risk during transport. Machine-applied stretch wrap with 3-5 revolutions plus corner boards is the minimum recommendation. For LTL shipments or hazmat loads, banding is also recommended.

What are the DOT requirements for shipping stacked pails?

DOT requires that all cargo be secured to prevent shifting, tipping, or falling during transport (49 CFR 393). For hazmat pails, additional requirements include upright orientation, visible UN markings, proper placarding, and compliance with the UN-rated stack test (equivalent to 3 containers high for 28 days at 104°F). All drivers must carry shipping papers for hazmat loads.

Key Takeaways

Empty 5-gallon HDPE pails weigh approximately 2 lbs; filled with water they weigh approximately 42 lbs
90-mil industrial HDPE pails support 60+ lbs of contents and 180 lbs of top-load stacking force
UN Y27 certification means maximum gross weight (pail + lid + contents) of 27 kg (59.5 lbs)
3 layers is the standard maximum for filled pail stacking in warehouse environments
12 pails per layer on a standard pallet with 36 filled or 108 empty per pallet
Stretch wrap plus corner boards reduces shipping damage claims by 85%
OSHA requires 18-inch clearance below sprinkler heads for all stacked materials
Reduce stack height by 1 layer when warehouse temperature exceeds 100°F

Calculate Your Pallet Configuration

Use PailHQ's free tools to plan your warehouse layout and ordering:

Pallet Calculator — Calculate how many pails fit on your pallet size
Pallet Quantity Guide — Standard configurations, truckload quantities, and bulk pricing
View Product Specifications — Full specs on our 90-mil industrial HDPE pails
Request a Bulk Quote — Get volume pricing for your specific application

Bulk pricing starts at $5.99/pail for 48+ units with free shipping on qualifying orders.