5 Gallon Bucket Dimensions: Exact Height, Width, Weight

Complete Guide to 5 Gallon Bucket Sizes, Dimensions & Specifications

Published: February 11, 2026 | PailHQ Technical Team | 18 min read

When it comes to 5-gallon buckets, dimensions matter more than most people realize. Whether you are calculating storage capacity for a warehouse, planning pallet configurations for a shipping operation, or simply trying to determine whether a lid from one manufacturer will fit a pail from another, knowing the exact measurements of a 5-gallon bucket is essential.

The challenge is that "5-gallon bucket" is a nominal description, not a precise engineering specification. Different manufacturers produce pails with slightly different heights, diameters, wall thicknesses, and actual capacities. These variations affect everything from how many buckets fit on a pallet to whether aftermarket accessories are compatible with your specific pail.

This guide provides the definitive reference for 5-gallon bucket dimensions, drawing on manufacturer specifications from M&M Industries, Leaktite, United Solutions, and other leading producers. We cover standard measurements, capacity variations, handle types, materials, pallet configurations, and the most common sizing mistakes that cost businesses time and money. Whether you are a procurement manager ordering thousands of pails or a homesteader looking for the right container, this guide has the data you need.

Standard 5-Gallon Bucket Dimensions

The standard 5-gallon bucket follows a well-established set of dimensions that have remained largely consistent across the industry for decades. These measurements are based on the open-head pail design, which is the most common configuration for 5-gallon containers used in food processing, chemical packaging, paint, and general industrial applications.

Overall Height

The standard height of a 5-gallon bucket body is 14.5 inches (368 mm) measured from the bottom of the pail to the top of the rim, not including the lid. This measurement represents the exterior height of the container body only.

When a snap-on or gasketed lid is installed, the total height increases. A standard cover adds approximately 1 3/8 inches (35 mm) to the overall height, bringing the total assembled height to approximately 15 7/8 inches (403 mm). This is a critical measurement for calculating shelf clearance, stacking height in warehouses, and shipping container utilization.

Top Diameter

The top outside diameter of a standard 5-gallon bucket is 11 7/8 inches (302 mm). This is measured across the widest point of the rim at the top of the pail. The top diameter is larger than the bottom diameter because 5-gallon buckets feature a tapered design that allows them to nest inside one another for efficient storage and shipping when empty.

The top inside diameter is slightly smaller than the outside measurement due to wall thickness. For a standard 90-mil wall, the inside top diameter is approximately 11.70 inches (297 mm).

Bottom Diameter

The bottom outside diameter of a standard 5-gallon bucket is 10 3/8 inches (263 mm). The narrower bottom serves two purposes: it allows for nesting (stacking empty pails inside one another), and it provides structural stability by creating a slightly wider footprint at the top where the wire bail handle attaches.

The bottom inside diameter, accounting for wall thickness, is approximately 10.19 inches (259 mm).

Wall Thickness

Standard industrial-grade 5-gallon pails feature a wall thickness of 90 mil (0.090 inches / 2.29 mm). This specification is particularly important for containers used in UN-certified hazmat transport, food-grade applications, and any situation where structural integrity under load is critical.

Wall thickness directly affects several performance characteristics:

Stacking strength: Thicker walls support greater vertical loads during pallet stacking
Drop resistance: 90-mil walls allow the pail to pass UN drop tests from 1.2 meters when filled to rated capacity
Chemical barrier properties: Thicker walls reduce permeation rates for volatile contents
Service life: Greater wall thickness extends the useful life of reusable containers

Some economy-grade buckets use thinner walls (as low as 60-70 mil), which reduces material cost but also reduces load capacity, chemical resistance, and overall durability. For industrial applications, 90-mil walls are the accepted standard.

Weight

An empty standard 5-gallon bucket weighs approximately 2.21 lbs (1.00 kg) per M&M Industries Traditional M2 specifications. This weight applies to the pail body with a wire bail handle but does not include the lid.

A standard snap-on or gasketed lid adds approximately 0.40-0.55 lbs (0.18-0.25 kg), bringing the total empty weight of a pail with lid to approximately 2.61-2.76 lbs (1.18-1.25 kg).

When filled with water at 62.3 lbs per cubic foot, a 5-gallon bucket holds approximately 41.7 lbs (18.9 kg) of water, making the total filled weight approximately 44 lbs (20 kg). For denser materials like paint (approximately 11-12 lbs per gallon), a filled 5-gallon bucket can weigh 57-62 lbs (26-28 kg).

Actual Capacity

The nominal "5-gallon" designation is based on the pail's working capacity, but the actual total volume of a standard 5-gallon bucket is typically 5.28 gallons (20.0 liters) when measured to the very top of the rim. The usable fill capacity, allowing for headspace to prevent spillage during handling and to accommodate a gasket lid seal, is approximately 5.0 gallons (18.93 liters).

This distinction between total volume and working capacity is important for quality control, fill line calibration, and regulatory compliance. See the section below on why "5 gallons" is not always exactly 5 gallons.

Cover (Lid) Dimensions

The standard cover for a 5-gallon pail has the following dimensions:

| Specification | Imperial | Metric |

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

| Cover outside diameter | 12 1/8 inches | 308 mm |

| Cover height | 1 3/8 inches | 35 mm |

| Cover weight | 0.40-0.55 lbs | 0.18-0.25 kg |

| Seal type | Gasket or friction fit | -- |

The cover outside diameter (12 1/8 inches) is slightly larger than the pail top diameter (11 7/8 inches) because the lid overlaps and snaps over the rim of the pail body. This overlap creates the seal and ensures the lid cannot fall into the container.

Complete M2 Specification Summary

The following table summarizes the key dimensions of the M&M Industries Traditional M2 5-gallon pail, which serves as an industry-standard reference:

| Specification | Imperial | Metric |

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

| Height (body only) | 14.5 inches | 368 mm |

| Height (with cover) | 15 7/8 inches | 403 mm |

| Top outside diameter | 11 7/8 inches | 302 mm |

| Bottom outside diameter | 10 3/8 inches | 263 mm |

| Wall thickness | 90 mil (0.090 in) | 2.29 mm |

| Pail weight (empty) | 2.21 lbs | 1.00 kg |

| Nominal capacity | 5.0 gallons | 18.93 liters |

| Overflow capacity | 5.28 gallons | 20.0 liters |

| Cover outside diameter | 12 1/8 inches | 308 mm |

| Cover height | 1 3/8 inches | 35 mm |

Why "5 Gallon" Isn't Always 5 Gallons

One of the most common sources of confusion in the bucket industry is the assumption that a "5-gallon bucket" always holds exactly 5 gallons. In reality, the actual volume of a 5-gallon bucket depends on how you measure it, what type of head configuration it uses, and how much headspace is required for your specific application.

Open Head vs Closed Head Measurements

5-gallon containers come in two primary configurations:

Open head (1H2 designation): The entire top of the container is open, with a removable lid that snaps or bolts onto the rim. This is the standard configuration for most 5-gallon buckets. The fill capacity is measured from the bottom of the pail to a fill line below the rim, typically leaving 0.5-1.0 inches of headspace.

Closed head (1H1 designation): The top of the container is permanently sealed as part of the manufacturing process, with one or two bung openings for filling and pouring. Closed-head containers are more common in drum sizes (15, 30, 55 gallons) but are available in 5-gallon configurations for certain liquid chemicals and solvents. The fill capacity of a closed-head container is measured differently because the entire internal volume is available for liquid, minus the volume occupied by the bung fittings.

For open-head 5-gallon pails, the total volume to the brim is typically 5.28 gallons (20.0 liters), while the working fill capacity is 5.0 gallons (18.93 liters). The difference of 0.28 gallons (1.06 liters) represents the headspace above the fill line.

Fill Line vs Overflow Capacity

The "fill line" on a 5-gallon bucket is not always marked, but it represents the maximum recommended fill level that allows for safe handling, lid installation, and thermal expansion of liquid contents. Filling a pail above the fill line creates several problems:

Lid interference: Overfilled pails may not seal properly because the liquid contacts the underside of the lid, preventing the gasket from seating correctly
Spill risk: Pails filled to the brim will spill when tilted during handling or transport
Pressure buildup: Sealed containers with no headspace cannot accommodate thermal expansion, potentially causing lid blowoff or container deformation
Regulatory non-compliance: UN-certified containers must maintain specified headspace requirements for hazmat transport

The overflow capacity (5.28 gallons) represents the absolute maximum volume the container can hold with liquid level at the very top of the rim. This measurement is useful for calculating theoretical maximum capacity but should never be used as the actual fill target for production operations.

How the Tapered Shape Affects Actual Volume

5-gallon buckets are not perfect cylinders. The tapered design (wider at the top, narrower at the bottom) means that the volume per inch of height is not uniform throughout the container. The top portion of the bucket contains more volume per inch than the bottom portion.

This matters for applications where partial fills are common. For example, filling a 5-gallon bucket to exactly half its height (7.25 inches) does not yield exactly 2.5 gallons of capacity. Because the lower portion has a smaller cross-sectional area, the actual volume at half height is approximately 2.2-2.3 gallons, depending on the specific taper ratio of the manufacturer.

For precise volume measurements at specific fill heights, the volume of a truncated cone (frustum) formula is required:

V = (pi/3) x h x (r1^2 + r1 x r2 + r2^2)

Where h is the fill height, r1 is the radius at the bottom, and r2 is the radius at the top of the filled portion.

Headspace Requirements by Application

Different applications require different amounts of headspace:

| Application | Recommended Headspace | Resulting Fill Volume |

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

| Non-hazardous liquids | 0.5 inches minimum | ~5.1 gallons |

| Hazmat liquids (UN certified) | 1.0 inch minimum (or per SDS) | ~5.0 gallons |

| Dry goods / powders | 0.25-0.5 inches | ~5.15 gallons |

| Hot-fill operations | 1.0-1.5 inches (thermal expansion) | ~4.8-5.0 gallons |

| Fermentation / gas-producing | 2.0+ inches | ~4.5 gallons |

Comparing Bucket Brands and Sizes

While the 5-gallon bucket market follows general dimensional standards, different manufacturers produce pails with subtle but meaningful variations. These differences affect compatibility with aftermarket lids, handles, and accessories, as well as pallet configurations and shipping efficiency.

M&M Industries

M&M Industries is one of the largest 5-gallon pail manufacturers in the United States, headquartered in Chatsworth, Georgia. Their Traditional M2 pail is widely considered the industry standard for open-head 5-gallon containers.

M&M Industries M2 Specifications:

Height: 14.5 inches
Top outside diameter: 11 7/8 inches
Bottom outside diameter: 10 3/8 inches
Wall thickness: 90 mil
Weight: 2.21 lbs
Capacity: 5.0 gallons (nominal) / 5.28 gallons (overflow)
Handle: Wire bail with plastic grip
Material: HDPE (virgin, food-grade available)
Colors: White (standard), black, blue, red, green, yellow, custom colors available
Pallet configuration: 120 pails (12 stacks x 10 high)
UN certification: Available (1H2/Y27/S)

M&M Industries pails are manufactured via injection molding, which provides excellent dimensional consistency, uniform wall thickness, and a smooth interior surface finish that is easier to clean than blow-molded containers. The M2 series is FDA food-grade compliant when ordered with food-grade resin certification.

Leaktite

Leaktite, now part of the Letica Corporation family, is a major supplier of 5-gallon buckets through retail channels including The Home Depot and Lowe's. Their consumer-grade 5-gallon buckets are among the most widely recognized in North America.

Leaktite Specifications (typical consumer-grade):

Height: 14.5 inches (nominal)
Top outside diameter: 11.75-11.91 inches
Bottom outside diameter: 10.25-10.40 inches
Wall thickness: 70-80 mil (thinner than industrial grade)
Weight: 1.75-1.90 lbs
Capacity: 5.0 gallons (nominal)
Handle: Wire bail with plastic grip
Material: HDPE (may include recycled content)
Colors: White, orange (Home Depot branded), blue

Leaktite buckets are generally lighter than M&M Industries pails due to thinner wall construction. While suitable for paint, general storage, and light-duty applications, the thinner walls make them less appropriate for UN-certified hazmat transport or heavy industrial use where stacking loads are significant.

United Solutions

United Solutions manufactures 5-gallon buckets primarily for retail distribution through Lowe's and other home improvement chains. Their pails are positioned as utility-grade containers.

United Solutions Specifications (typical):

Height: 14.5 inches (nominal)
Top outside diameter: 11.75-11.88 inches
Bottom outside diameter: 10.25-10.38 inches
Wall thickness: 70-85 mil
Weight: 1.80-2.00 lbs
Capacity: 5.0 gallons (nominal)
Handle: Wire bail with plastic grip
Material: HDPE

Dimensional Comparison Table

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

| Height | 14.5" | 14.5" | 14.5" |

| Top OD | 11 7/8" (11.875") | 11.75-11.91" | 11.75-11.88" |

| Bottom OD | 10 3/8" (10.375") | 10.25-10.40" | 10.25-10.38" |

| Wall thickness | 90 mil | 70-80 mil | 70-85 mil |

| Weight | 2.21 lbs | 1.75-1.90 lbs | 1.80-2.00 lbs |

| UN certifiable | Yes | No | No |

Key Differences Between Brands

Wall thickness is the most significant differentiator between industrial and consumer-grade 5-gallon buckets. The 90-mil wall of an M&M Industries M2 pail provides approximately 15-30% more material than the 70-80 mil walls found on typical consumer buckets. This additional material translates to greater stacking strength, better drop resistance, improved chemical barrier properties, and qualification for UN hazmat certification.

Weight varies accordingly. The heavier M2 pail (2.21 lbs) uses more resin per unit than lighter consumer alternatives (1.75-2.00 lbs). While the per-unit cost is higher, the improved performance characteristics justify the investment for industrial applications where container failure would be costly or dangerous.

Handle types are another area of variation. Most manufacturers use a wire bail handle with a molded plastic grip, but the wire gauge, grip design, and attachment method differ. Some economy handles use thinner wire that can flex under heavy loads, while industrial-grade handles use heavier gauge wire rated for the full filled weight of the container.

Lid compatibility is a common concern when mixing brands. While most 5-gallon bucket lids follow similar dimensional standards, slight variations in rim profile and diameter mean that a lid from one manufacturer may fit loosely or tightly on a pail from another manufacturer. For applications requiring airtight seals (food storage, chemical containment), it is strongly recommended to use matched lid and pail combinations from the same manufacturer.

Handle Types and Specifications

The handle on a 5-gallon bucket is more than a convenience feature. It is an engineered component that must support the full weight of a filled container during lifting, carrying, and pouring operations. Understanding handle types helps in selecting the right bucket for your application.

Wire Bail Handles

The most common handle type for 5-gallon buckets is the wire bail handle. This design uses a galvanized or zinc-plated steel wire formed into a U-shape that pivots on lugs molded into the sides of the pail body.

Specifications:

Wire gauge: 9-11 gauge (0.114-0.148 inch diameter)
Material: Galvanized steel or zinc-plated carbon steel
Grip: Molded plastic sleeve (polypropylene or HDPE)
Carry rating: 60-70 lbs (typical)
Pivot type: Molded lug (integrated into pail body)

Wire bail handles offer several advantages: they fold flat against the pail body for nesting and stacking, they are inexpensive to manufacture, and they provide reliable strength for carrying filled containers. The plastic grip sleeve distributes the load across the palm and provides a comfortable carrying surface.

Plastic Handles

Some 5-gallon buckets use molded plastic handles instead of wire bail handles. These are more common on consumer-grade buckets and specialty containers where metal-free construction is required (for example, in MRI suites or other environments with strong magnetic fields).

Specifications:

Material: Polypropylene or high-impact HDPE
Carry rating: 40-55 lbs (lower than wire bail)
Pivot type: Molded hinge or snap-in connection

Plastic handles are generally lighter and less expensive than wire bail handles, but they have lower carry ratings and are more susceptible to UV degradation and fatigue failure over time. They are not recommended for heavy industrial applications or containers that will be lifted repeatedly at maximum fill weight.

No-Handle Options

Certain 5-gallon pails are available without handles, particularly those designed for automated filling lines where handles would interfere with conveyor systems, filling nozzles, or labeling equipment. Handle-free pails rely on the rim and body taper for manual handling and are typically used only in environments with mechanical lifting equipment.

Handle Load Ratings

| Handle Type | Typical Carry Rating | Best Application |

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

| Wire bail (heavy gauge) | 65-70 lbs | Industrial, chemical, paint |

| Wire bail (standard gauge) | 55-65 lbs | General purpose, food storage |

| Plastic molded | 40-55 lbs | Light-duty, retail, consumer |

| No handle | N/A (mechanical handling) | Automated filling lines |

When selecting a handle type, consider the density of the contents. Water weighs approximately 8.34 lbs per gallon (41.7 lbs for 5 gallons), while denser materials like paint (10-12 lbs per gallon) or chemical concentrates can push total filled weight to 60+ lbs, approaching the limits of lighter handle designs.

Materials and Construction

The material composition and manufacturing process of a 5-gallon bucket determine its chemical compatibility, regulatory certifications, structural performance, and service life. Understanding these factors is essential for selecting the right container for your application.

HDPE Resin Grades

Virtually all 5-gallon buckets are manufactured from high-density polyethylene (HDPE), a thermoplastic polymer with excellent chemical resistance, impact strength, and processability. However, not all HDPE is the same. Different resin grades are formulated for different performance requirements:

Injection molding grade HDPE has a higher melt flow index (MFI) of 4-12 g/10 min, allowing it to flow easily into complex mold geometries. This grade is used for pails manufactured via injection molding, such as the M&M Industries M2 series. Injection molding grades produce containers with precise dimensional control and uniform wall thickness.

Blow molding grade HDPE has a lower melt flow index (MFI) of 0.2-1.0 g/10 min, providing higher melt strength to maintain the parison (molten tube) shape during the blow molding process. Blow-molded pails may exhibit slightly greater wall thickness variation compared to injection-molded containers.

Food-grade HDPE must comply with FDA 21 CFR 177.1520, which restricts the types of additives, stabilizers, and colorants that can be used. Food-grade resins use only FDA-approved antioxidants and contain no recycled content. The resin supplier must provide a letter of compliance (LOC) documenting conformance with FDA regulations.

UN-rated HDPE is formulated for enhanced environmental stress crack resistance (ESCR) and impact strength to meet the drop test, stack test, and leak-proof test requirements of UN performance packaging standards. These resins typically have higher molecular weight and tighter density specifications than general-purpose grades.

Injection Molding vs Blow Molding

The two primary manufacturing processes for 5-gallon buckets each have distinct advantages:

Injection molding forces molten HDPE under high pressure (10,000-30,000 psi) into a two-piece mold cavity. The result is a container with precise dimensional tolerances (+/- 0.005 inches on wall thickness), smooth interior and exterior surfaces, and consistent weight from part to part. Injection-molded pails are preferred for food-grade applications because the smooth surface is easier to clean and less likely to harbor bacteria.

Blow molding inflates a heated HDPE tube (parison) inside a mold cavity using compressed air. This process is well-suited for producing containers with integrated handles and more complex geometries. However, blow-molded containers typically exhibit greater wall thickness variation (up to +/- 15%) because the material distribution depends on parison programming and mold geometry rather than direct injection pressure.

Most industrial-grade 5-gallon pails, including the M&M Industries M2 series, are injection molded. Many consumer-grade buckets sold through retail channels are blow molded.

Recycled Content Considerations

HDPE containers can incorporate post-consumer recycled (PCR) or post-industrial recycled (PIR) content, but with important limitations:

Food-grade containers: FDA regulations significantly restrict the use of recycled content in food-contact containers. Most food-grade 5-gallon pails use 100% virgin HDPE resin
Industrial containers: Can incorporate 25-100% recycled HDPE content, depending on the application requirements
UN-certified containers: Recycled content use is generally restricted because the mechanical properties of recycled resin may not meet the stringent drop test and stack test requirements

Recycled HDPE typically has slightly lower impact strength and ESCR compared to virgin resin due to polymer chain degradation during the recycling process. For applications where maximum performance is required, virgin HDPE remains the standard.

Color Options

Standard 5-gallon buckets are most commonly produced in white, which serves as the industry default for several reasons:

White HDPE uses titanium dioxide (TiO2) pigment, which provides UV protection and extends outdoor service life
White containers allow easy visual inspection of interior cleanliness
White is compatible with food-grade and pharmaceutical applications
White provides a neutral background for label application

Additional standard colors include black, blue, red, green, and yellow. Custom colors are available for large-volume orders (typically 5,000+ units minimum), using FDA-approved pigment concentrates for food-grade applications or standard industrial pigments for non-food applications.

Color coding is commonly used in industrial facilities to identify container contents by category: white for food-grade, blue for cleaning chemicals, red for hazardous materials, green for agricultural products, and yellow for waste or recycling.

Pallet Configuration and Shipping

Efficient pallet configuration is critical for minimizing shipping costs and maximizing warehouse utilization. The standard 5-gallon bucket is designed to nest and stack in configurations that optimize common pallet and truck dimensions.

Standard Pallet Configuration

Per M&M Industries specifications, the standard pallet configuration for 5-gallon buckets is:

Pails per pallet: 120
Configuration: 12 stacks x 10 pails high
Pallet size: 48" x 40" (standard GMA pallet)
Stack height (empty, nested): Approximately 48-52 inches (10 pails nested)
Pallet weight (empty pails only): Approximately 265 lbs (120 x 2.21 lbs)

The 12-stack arrangement places pails in a pattern that fills the 48" x 40" pallet footprint efficiently, with each pail's 11 7/8" top diameter allowing for three rows of four stacks across the pallet surface.

Truckload Quantities

For full truckload (FTL) shipments:

Pails per truckload: 6,720 (56 pallets x 120 pails)
Pallets per truck: 56 (double-stacked on a 53-foot trailer)
Truck type: 53-foot dry van trailer
Estimated gross weight: Approximately 17,000 lbs (empty pails + pallets)

For less-than-truckload (LTL) shipments, 5-gallon buckets ship as NMFC Class 150-175 depending on whether they are nested or filled. Empty nested pails ship at a lower class due to their favorable density ratio.

Nesting Ratio

One of the key advantages of the tapered 5-gallon bucket design is the nesting ratio. When empty, pails stack inside one another with each additional pail adding only 1.5-2.0 inches to the total stack height. This means:

1 pail: 14.5 inches tall
10 pails nested: approximately 32-33 inches tall
Nesting savings: approximately 80% reduction in stack height compared to non-nested shipping

This nesting efficiency dramatically reduces shipping costs for empty containers. A truck that can carry 6,720 empty nested pails would only carry approximately 1,400 filled pails at the same weight limit.

Shipping Class and Freight Considerations

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

Freight costs for 5-gallon buckets are significantly affected by whether the pails are shipped empty or filled. Empty nested pails have a very low density, which means they "cube out" (fill the truck by volume) long before they "weigh out" (reach the truck's weight limit). This results in higher per-pound shipping costs but lower per-unit costs.

For filled pails, the opposite is true. Dense contents like paint or chemicals can cause the truck to reach its weight limit before the trailer is full by volume. In these cases, optimizing pallet configuration and using lightweight container designs can improve shipping economics.

Warehouse Storage

When planning warehouse storage for palletized 5-gallon buckets, account for the following clearance requirements:

Minimum aisle width: 12 feet for forklift access
Maximum stack height: 3 pallets high for empty pails (per OSHA recommendations)
Maximum stack height: 2 pallets high for filled pails (weight-dependent)
Sprinkler clearance: Minimum 18 inches below sprinkler heads (per NFPA 13)

Volume Conversions and Capacity

Understanding the volumetric equivalents of a 5-gallon bucket is essential for recipe scaling, ingredient measuring, and capacity planning. The following conversions are based on the standard 5.0-gallon (nominal) working capacity.

Standard Volume Conversions

| Unit | 5-Gallon Equivalent | Per Gallon |

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

| U.S. gallons | 5.0 | 1.0 |

| U.S. quarts | 20 | 4 |

| U.S. pints | 40 | 8 |

| U.S. cups | 80 | 16 |

| U.S. fluid ounces | 640 | 128 |

| Liters | 18.93 | 3.785 |

| Milliliters | 18,927 | 3,785 |

| Cubic inches | 1,155 | 231 |

| Cubic feet | 0.668 | 0.1337 |

| Imperial gallons | 4.16 | 0.832 |

Weight by Content Type

The weight of a filled 5-gallon bucket varies significantly depending on the density of the contents:

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

| Water | 8.34 lbs | 41.7 lbs | 43.9 lbs |

| Latex paint | 10.5-11.5 lbs | 52.5-57.5 lbs | 54.7-59.7 lbs |

| Motor oil | 7.5 lbs | 37.5 lbs | 39.7 lbs |

| Honey | 11.8-12.0 lbs | 59.0-60.0 lbs | 61.2-62.2 lbs |

| Sand (dry) | 13.5 lbs | 67.5 lbs | 69.7 lbs |

| Concrete (mixed) | 20.0 lbs | 100.0 lbs | 102.2 lbs |

| Wheat flour | 4.5 lbs | 22.5 lbs | 24.7 lbs |

| Rice (dry) | 7.0 lbs | 35.0 lbs | 37.2 lbs |

| Gravel | 13.0 lbs | 65.0 lbs | 67.2 lbs |

Practical Capacity Notes

When using a 5-gallon bucket for dry goods such as grains, flour, or sugar, the actual usable capacity depends on the particle size and packing density of the material. Fine powders like flour pack more densely than coarse grains like rice or beans, so the weight per bucket varies even though the volume remains constant.

For bulk dry food storage, a 5-gallon bucket typically holds:

25 lbs of rice (approximately 4.5 gallons of settled volume)
25 lbs of wheat berries (approximately 4.2 gallons of settled volume)
22-25 lbs of all-purpose flour (approximately 4.8 gallons of settled volume)
33-35 lbs of granulated sugar (approximately 4.5 gallons of settled volume)
25-30 lbs of dry beans (approximately 4.0 gallons of settled volume)

These values assume the material is poured in and settled, not compacted. Vibration or tamping can increase the density and total weight by 10-15%.

Common Sizing Mistakes to Avoid

Procurement managers, warehouse operators, and DIY users all make predictable errors when working with 5-gallon bucket dimensions. Avoiding these mistakes can prevent compatibility issues, regulatory problems, and wasted inventory.

Mistake 1: Measuring Inside Diameter Instead of Outside Diameter

Bucket dimensions in manufacturer specifications are almost always given as outside dimensions. The outside diameter at the top of a standard 5-gallon bucket is 11 7/8 inches, while the inside diameter is approximately 11.70 inches. When specifying lids, gaskets, or liners, it is critical to know whether the vendor requires inside or outside measurements. Using the wrong reference dimension can result in lids that do not seal properly or liners that are too small to fit the container.

Mistake 2: Confusing Nominal Capacity with Actual Volume

A "5-gallon bucket" is not precisely 5.000 gallons. The nominal capacity of 5.0 gallons represents the recommended working fill level, while the actual volume to the brim is typically 5.28 gallons. Using the overflow capacity (5.28 gallons) as a fill target will result in spillage, lid sealing failures, and potential regulatory non-compliance for hazmat containers.

Conversely, assuming exactly 5.000 gallons for production planning may result in underfilling if the bucket's actual working capacity is slightly more than 5.0 gallons due to dimensional tolerances.

Mistake 3: Not Accounting for Lid Height

When calculating total stacking height or shelf clearance for palletized 5-gallon buckets with lids, many people use the pail body height of 14.5 inches and forget to add the lid height of 1 3/8 inches. The total height of a sealed 5-gallon bucket is approximately 15 7/8 inches. Over a stack of 10 filled and lidded pails, this error accumulates to nearly 14 inches of unaccounted height, which can cause clearance problems with shelving, doorways, or truck interior heights.

Mistake 4: Assuming All Brands Are Interchangeable

While the 5-gallon bucket market follows general dimensional standards, variations between manufacturers in rim profile, wall thickness, and taper angle mean that lids, handles, and accessories from one brand may not fit perfectly on pails from another. For applications requiring reliable airtight seals, always verify lid-to-pail compatibility before committing to a cross-brand configuration.

Mistake 5: Ignoring Nesting Depth for Empty Storage

When storing empty buckets, the nesting depth (how far each bucket sinks into the one below it) determines total stack height. Nesting depth varies by manufacturer based on the internal geometry of the pail bottom. Some pails have a flat bottom interior, while others have a recessed center panel that affects nesting depth. Failure to account for this variation can result in empty pail stacks that are taller or shorter than planned.

Mistake 6: Using Imperial When Metric Is Required

International shipments, scientific applications, and manufacturing environments in metric-system countries require metric dimensions. Specifying a bucket as "5 gallons" without providing the metric equivalent (18.93 liters) can cause confusion and ordering errors. Always confirm whether your customer or regulatory body requires Imperial or metric units.

Choosing the Right Size for Your Application

While the 5-gallon bucket is the most popular container size in North America, it is not always the best choice. Understanding when to use a 5-gallon bucket versus when to size up or size down ensures you get the most efficient and cost-effective container for your needs.

When 5-Gallon Is Ideal

The 5-gallon bucket is the optimal choice for applications that meet the following criteria:

Weight manageable by one person: A filled 5-gallon bucket of most liquids weighs 40-60 lbs, which is within the single-person manual lifting range (OSHA recommends a maximum of 51 lbs for routine lifting)
Standard pallet compatibility: 120 pails fit on a standard 48" x 40" GMA pallet, making 5-gallon buckets highly efficient for warehousing and shipping
Portion-appropriate quantities: Many industrial products (paint, adhesives, cleaning chemicals, food ingredients) are sold and consumed in 5-gallon increments
Regulatory compliance available: FDA food-grade and UN hazmat certifications are widely available for 5-gallon HDPE pails
Reusable and stackable: The 5-gallon size is practical for refilling, cleaning, and reusing in secondary applications

Common applications ideally suited for 5-gallon buckets include paint and coatings, cleaning chemicals, food ingredients (flours, oils, syrups), agricultural chemicals, adhesives and sealants, and emergency water storage.

When to Size Up: 30-Gallon and 55-Gallon Drums

Consider larger containers when:

High-volume consumption: If your operation uses more than 10 five-gallon buckets per day of the same product, a 55-gallon drum reduces handling labor and packaging waste
Cost per gallon optimization: Larger containers generally have a lower packaging cost per gallon of contents
Reduced waste: Fewer containers means fewer lids, handles, and labels to dispose of or recycle
Automated dispensing: Drum-mounted pumps and dispensing systems work more efficiently with larger containers

A 55-gallon drum holds the equivalent of 11 five-gallon buckets. For high-volume operations, switching from 5-gallon buckets to 55-gallon drums can reduce packaging costs by 40-60% and significantly reduce labor for opening, emptying, and disposing of containers.

When to Size Down: 1-Gallon to 3.5-Gallon Containers

Smaller containers are appropriate when:

Weight sensitivity: Products that are very dense (concrete mix, sand, certain chemicals) may exceed safe manual lifting weight in a 5-gallon container
Retail packaging: Consumer products sold through retail channels often require 1-gallon or 2.5-gallon sizes for shelf compatibility and consumer convenience
Portion control: Applications requiring precise measured quantities benefit from smaller, pre-measured containers
Shelf life concerns: Products with limited shelf life should be packaged in quantities that will be consumed before expiration
Specialty applications: Some products require specific container sizes for compatibility with dispensing equipment, spray systems, or mixing ratios

Common smaller container sizes include:

| Size | Capacity (oz) | Typical Application |

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

| 1 gallon | 128 oz | Retail paint, consumer chemicals, food service |

| 2 gallon | 256 oz | Adhesives, specialty coatings, food service |

| 2.5 gallon | 320 oz | Agricultural chemicals, cleaning concentrates |

| 3.5 gallon | 448 oz | Ice cream, food processing, large retail |

Total Cost of Ownership Considerations

When choosing container size, consider the total cost of ownership, not just the container price:

Container cost per gallon of contents
Lid/closure cost per container
Label cost per container
Labor cost for filling, sealing, and handling
Shipping cost per gallon of contents
Storage space cost per gallon of contents
Disposal/recycling cost per container

In most cases, the 5-gallon bucket provides the best balance of these factors for moderate-volume applications, which is why it remains the single most popular container size in North American industrial packaging.

Frequently Asked Questions

What are the exact dimensions of a 5-gallon bucket?

A standard 5-gallon bucket measures 14.5 inches tall (368 mm) with a top outside diameter of 11 7/8 inches (302 mm) and a bottom outside diameter of 10 3/8 inches (263 mm). The standard wall thickness is 90 mil (0.090 inches / 2.29 mm), and the empty weight is approximately 2.21 lbs (1.00 kg) per the M&M Industries M2 specification. With a standard lid installed, the total height is approximately 15 7/8 inches (403 mm).

How many gallons does a 5-gallon bucket actually hold?

A standard 5-gallon bucket has a nominal working capacity of 5.0 gallons (18.93 liters) and an overflow capacity of 5.28 gallons (20.0 liters) when filled to the absolute brim. The 0.28-gallon difference represents the headspace above the fill line that is recommended for safe handling, lid sealing, and thermal expansion.

Will a lid from one brand fit a different brand's bucket?

Most 5-gallon bucket lids follow similar dimensional standards, but slight variations in rim profile, top diameter, and wall thickness between manufacturers mean that cross-brand compatibility is not guaranteed. A lid that snaps securely onto an M&M Industries pail may fit loosely on a Leaktite bucket, or vice versa. For applications requiring airtight seals, always use matched lid-and-pail combinations from the same manufacturer.

How much does a 5-gallon bucket weigh when full?

The weight of a filled 5-gallon bucket depends on the density of the contents. Filled with water, a 5-gallon bucket weighs approximately 43.9 lbs (bucket weight of 2.21 lbs plus water weight of 41.7 lbs). Filled with latex paint, the total weight can reach 57-60 lbs. Filled with concrete, the total weight can exceed 100 lbs.

How many 5-gallon buckets fit on a pallet?

The standard pallet configuration for 5-gallon buckets is 120 pails per pallet, arranged in 12 stacks of 10 pails each on a standard 48" x 40" GMA pallet. A full truckload on a 53-foot trailer holds approximately 56 pallets, or 6,720 pails.

Are all 5-gallon buckets food safe?

No. A 5-gallon bucket is food safe only if it is manufactured from FDA-compliant HDPE resin under 21 CFR 177.1520, uses only FDA-approved additives and colorants, and is certified by the manufacturer as food-grade. Industrial-grade buckets may contain non-food-safe pigments, recycled content, or additives that are not approved for food contact. Always verify food-grade certification before using any bucket for food storage.

What is the difference between a pail and a bucket?

In industry usage, "pail" and "bucket" refer to the same container. "Pail" is the more common term in industrial and regulatory contexts (e.g., UN performance packaging standards reference "pails"), while "bucket" is the more common term in consumer and retail contexts. There is no dimensional or functional difference between the two terms.

Can 5-gallon buckets be stacked when full?

Yes, 5-gallon HDPE buckets with 90-mil walls can be stacked when filled, but with limitations. Per UN stack test requirements, a filled 5-gallon pail must support the equivalent weight of three identical filled containers stacked on top for 28 days at 104 degrees F (40 degrees C). In practice, most industrial-grade 5-gallon pails can safely support 2-3 filled pails stacked directly on top without a pallet. For higher stacking, palletized configurations with proper weight distribution are recommended.

Key Takeaways

Standard height is 14.5 inches (368 mm) for the pail body; total height with lid is approximately 15 7/8 inches (403 mm)
Top outside diameter is 11 7/8 inches (302 mm) and bottom outside diameter is 10 3/8 inches (263 mm), creating the tapered shape that enables nesting
Actual capacity is 5.28 gallons to the brim, but the nominal working fill is 5.0 gallons with appropriate headspace
Wall thickness of 90 mil is the industrial standard; consumer-grade buckets may use 70-80 mil walls with reduced performance
Empty weight is 2.21 lbs (1.00 kg) per M&M Industries M2 specifications, not including the lid
120 pails per pallet in a 12 x 10 configuration on a standard 48" x 40" GMA pallet, with 6,720 pails per truckload
Always verify lid-to-pail compatibility when mixing brands, as slight dimensional variations between manufacturers can affect seal integrity
5 gallons equals 20 quarts, 40 pints, 80 cups, 640 fluid ounces, 18.93 liters, or 1,155 cubic inches for volume conversion reference

Get the Right 5-Gallon Pails for Your Operation

PailHQ supplies industrial-grade 5-gallon HDPE pails built to M&M Industries M2 specifications. Our pails feature 90-mil wall thickness, wire bail handles, and are available in FDA food-grade and UN-certified configurations.

View Product Specifications | Request a Quote

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

Need help selecting the right container for your application? Call our team at 954-594-2108 or request a custom quote for volume pricing on 120+ unit orders.

Related Resources

5 Gallon Bucket DIY Projects — Creative projects using 5-gallon pails
5 Gallon Bucket Gardening Guide — Container gardening with HDPE buckets
5 Gallon Bucket Brewing & Fermentation Guide — Homebrewing in food-grade pails
HDPE Chemical Compatibility Guide — Full compatibility chart for HDPE containers
Ultimate 5 Gallon Pail Buying Guide — Everything you need to know before ordering

Sources

M&M Industries. Traditional M2 5-Gallon Pail Specification Sheet. Chatsworth, GA.
United Nations Economic Commission for Europe. Recommendations on the Transport of Dangerous Goods: Model Regulations. 22nd Revised Edition.
U.S. Food and Drug Administration. 21 CFR 177.1520 - Olefin Polymers. Code of Federal Regulations.
U.S. Department of Transportation. 49 CFR Part 178 - Specifications for Packagings. Code of Federal Regulations.
National Fire Protection Association. NFPA 13 - Standard for the Installation of Sprinkler Systems. 2025 Edition.
Occupational Safety and Health Administration. Ergonomic Guidelines for Manual Material Handling. OSHA Publication 3123.
National Motor Freight Traffic Association. National Motor Freight Classification (NMFC). Current Edition.
ASTM International. ASTM D1693 - Standard Test Method for Environmental Stress-Cracking of Ethylene Plastics. West Conshohocken, PA.