Pallet Repair & Refurbishment
Extend the life of your pallets through repair. Pallet repair is available through partner suppliers, and repaired pallets often cost less than new ones.
Request a Quote
Fill out the form and a partner supplier will follow up with a customized quote.
What Can Be Repaired
From minor board replacements to full structural rebuilds, pallet repairers commonly handle many types of pallet damage. Which repairs a supplier offers depends on the supplier.
Board Replacement
Cracked, split, or missing deck boards are replaced with matching lumber. Consistent board thickness and spacing matter for safe forklift entry and load distribution.
Stringer Repair
Broken or cracked stringers are commonly reinforced with companion boards or fully replaced. Stringer integrity is critical because it bears much of the load weight.
Lead Board Repair
The outermost deck boards take the most abuse. Damaged lead boards are replaced and fastened properly to help prevent future splitting.
Block Replacement
For block-style pallets, damaged or crushed blocks are removed and replaced with blocks of matching dimensions and wood type.
Renailing & Fastener Work
Loose nails are pulled and replaced. Ring-shank and screw-shank nails are commonly used because they hold better than smooth-shank nails.
Full Refurbishment
Pallets that need extensive work can be taken apart, have compromised components replaced, and be reassembled. Whether this makes sense depends on the pallet's condition and the cost.
Signs of a
Well-Repaired Pallet
A repaired pallet can be a sound choice when the repair is done well. Standards vary by supplier, so here is what to look for and ask about when you request a quote.
Structural Integrity
Stringers and blocks should carry the pallet's load without flexing or cracking. Load ratings are typical figures, so confirm the rating with the supplier.
Board Coverage
Deck boards should sit flush with even spacing so product is supported and forklift tines enter cleanly.
Fastener Quality
Fasteners should be seated flush. There should be no protruding nail heads or points that could damage product or injure handlers.
Dimensional Accuracy
Repaired pallets should stay close to their original dimensions, which matters for racking and automated systems.
Cleanliness
Pallets should be free of heavy dirt, debris, mold, and chemical residue. Mention any cleanliness needs in your request.
Repair vs. Buying New
Repaired pallets often cost less than new ones. Ask for a quote to compare the options for your pallets.
New Pallet
Typically a higher up-front cost
Repaired Pallet
Often costs less than new
Costs vary
Actual costs depend on the pallet, the damage, the quantity, and the supplier.
Also consider: repairing a pallet avoids building a new one and keeps a usable pallet out of the landfill.
Levels of Repair
Minor Repairs
Board replacements and renailing. Usually the quickest and lowest-cost type of repair.
Standard Repairs
Stringer repairs, lead board replacement, and multi-board fixes. These take more labor and materials per pallet.
Full Refurbishment
Complete teardown and rebuild, with a structural assessment, replacement of compromised components, and a final check.
Need Pallets Back on a Schedule?
Timing varies by supplier, repair type, and quantity. If you have a deadline, say so in your request and the supplier can tell you what is possible.
How to Get Your Pallets Repaired
Pickup & Return
Some suppliers collect damaged pallets, repair them at their own site, and return them. This can suit businesses with limited space for repair work. Pickup may be available through partner suppliers.
- Availability depends on the supplier
- Minimum quantities vary
- Ask about return delivery
Drop Off Yourself
Some suppliers accept pallets you bring in yourself, by arrangement. Dropping off can cut out transit time, but confirm with the supplier first rather than arriving unannounced.
- Arrange it with the supplier first
- Minimums vary by supplier
- Ask how drop-off timing works
Repair vs. Replace: What to Compare
The right answer depends on your pallets and your volume. Pricing is by quote from partner suppliers, so here is what to compare when you request one.
Option A: Buy New Pallets
Replacing damaged pallets with new ones of the same size.
Option B: Repair or Buy Recycled
Repairing what can be saved and buying recycled pallets to fill the gap.
Tip: Send a count of your damaged pallets and a few photos with your request. It helps a supplier tell you how many are worth repairing and how many are better recycled.
Common Pallet Damage Types & Typical Repairs
These are the damage types that come up most often in pallet repair. Here is what commonly causes each one and how it is typically repaired.
Split Deck Boards
Usually minorCaused by forklift tines striking the top deck during loading, or by heavy point loads exceeding the board's capacity. Most common at the lead board position where forklifts enter.
The split board is removed and replaced with a board of matching species, thickness, and width. Ring-shank nails are commonly used for better holding power.
Cracked Stringers
ModerateStringers crack when pallets are dropped from height, overloaded beyond rated capacity, or struck by forklift impacts at the notch points. Stringer damage is the most structurally critical type.
For partial cracks, a companion board of matching lumber can be fastened alongside the cracked stringer to restore load-bearing capacity. Fully fractured stringers are typically removed and replaced.
Missing or Broken Lead Boards
Usually minorThe outermost deck boards (lead boards) absorb the most impact during handling. They break from fork strikes, edge drops, and lateral impacts during conveyor transport.
Broken lead boards are replaced, sometimes with slightly thicker stock for durability at this high-impact position, and fastened securely.
Protruding or Loose Nails
Usually minorRepeated loading cycles, vibration during transit, and humidity changes cause nails to back out over time. Protruding nails are a safety hazard and can damage products and packaging.
Loose nails are pulled and replaced, often with ring-shank or screw-shank nails that hold better than smooth-shank nails. Extra fasteners may be added at joints showing movement.
Crushed Blocks (Block Pallets)
ModerateBlock pallets fail when blocks are crushed by excessive weight, moisture softening, or repeated racking impacts.
Damaged blocks are removed and replaced with blocks of matching dimensions. Screws are sometimes used for a more secure connection than nails.
Warped or Bowed Deck
Minor to moderateExposure to rain, direct sun, or uneven loading causes boards to warp or bow. This is especially common with pallets stored outdoors in Arizona's extreme heat and occasional monsoon rains.
Severely warped boards are replaced. Mildly warped boards can sometimes be flipped and renailed. Covered storage helps prevent the problem from recurring.
What to Ask a
Repair Supplier
A repaired pallet is only as good as the checks that follow the work. Practices vary by supplier, so these are good questions to raise when a supplier follows up on your request.
1. Visual Inspection
Are all surfaces checked for cracks, splits, missing components, and contamination before a pallet is released?
2. Dimensional Check
Are length, width, and height checked against the original spec, especially if the pallets go into racking or automated systems?
3. Fastener Check
Are nail heads seated flush, and are protruding nails driven or replaced?
4. Load Rating
What load rating does the supplier give for repaired pallets, and is it a static, dynamic, or racked figure? Ratings are typical, so confirm with the supplier.
5. Fork Entry
Do forklift tines enter every opening cleanly, without binding or catching?
6. Contamination
Are pallets with oil stains, chemical residue, mold, or odor set aside?
7. Grading
How does the supplier describe its grades? There is no single legal grade definition, so ask what each grade means.
Inspect on Receipt
Whatever a supplier's process, it is good practice to inspect repaired pallets when they arrive and before you load heavy product. Set aside any that look unsound and raise the issue with the supplier right away.
Need Repairs on a Deadline?
Timing varies by supplier
When production cannot wait, say so in your request. Whether a supplier can prioritize your job depends on the supplier, the repair type, and the quantity.
Frequently Asked Questions
How is it decided whether to repair or scrap a pallet?
Repairers typically inspect each pallet and repair it when structural integrity and safety can be restored. Pallets that cannot be restored are usually dismantled for lumber or ground, depending on the recycler.
Do repaired pallets cost less than new?
Repaired pallets often cost less than new ones of the same size. Pricing is by quote from partner suppliers, so request a quote to compare.
Do repaired pallets come with a warranty?
Terms vary by supplier. Ask the supplier what, if anything, they offer for repaired pallets and get it in writing before you accept a quote.
Can pallets be repaired on-site at my facility?
Most pallet repair is done at the supplier's own site. On-site work, if available, depends on the supplier and the quantity, so mention it in your request.
How long does a repair order take?
Timing depends on the supplier, the type of repair, and the quantity. A partner supplier follows up with an estimate once they know what you have.