Can You Use Pallet Wood for Decking?
An In‑Depth, Step‑by‑Step Guide for the DIY‑Savvy Homeowner
If you’ve ever walked past a stack of free or cheap pallets and imagined a rustic‑looking deck in your backyard, you’re not alone. Pallet wood is cheap, abundant, and has that reclaimed‑warehouse vibe that many designers love. But before you start hauling a mountain of pallets onto your property, you need to know whether the material is truly suitable for a surface that will bear your weight, your furniture, and the occasional summer party.
In this post we’ll walk you through everything you need to consider, from the structural realities of pallet lumber to the finishing touches that will keep your deck looking great for years. We’ll also give you handy tables to compare pallet wood with traditional decking options, and answer the most common questions at the end.
1. Why Pallet Wood Looks So Tempting
| Reason | What It Means for You |
|---|---|
| Cost | New pressure‑treated decking can run $3–$7 per square foot. Pallet boards are often free or cost a few dollars per pallet. |
| Aesthetic | Rough‑sawn, reclaimed look that can be left natural or stained for a weathered vibe. |
| Availability | Millions of pallets are discarded each year; many retailers and warehouses will give them away. |
| Environmental Appeal | Using reclaimed wood reduces waste and the demand for freshly cut lumber. |
All of those benefits are compelling, but they’re only the start of the story. The biggest question remains: Can pallet wood actually stand up to the demands of a deck?
2. The Structural Reality of Pallet Lumber
2.1 What Kind of Wood Are Pallets Made From?
Not all pallets are created equal. The most common species you’ll encounter in the United States are:
| Species (Typical) | Approx. Density (lb/ft³) | Natural Resistance | Typical Use |
|---|---|---|---|
| Pine (Southern, Spruce, Douglas) | 30–38 | Low (prone to rot) | General shipping |
| Oak (Red, White) | 45–55 | Moderate (good strength) | Heavy‑duty pallets |
| Hard Maple | 44–47 | Moderate | Specialty pallets |
| Mixed Softwood | 30–35 | Low | Cheap bulk pallets |
If you can identify the wood, you’ll have a better sense of durability. Pine and spruce are the most common but also the most vulnerable to moisture, while oak offers far better load‑bearing capacity.
2.2 Load‑Bearing Capacity
A standard “shipping” pallet (48” × 40”) is designed to support ≈ 1,500–2,000 lb when evenly distributed. However, that rating assumes the pallet is intact, with all its boards and nails in place. When you dismantle a pallet and use the individual planks for a deck, you lose the cross‑bracing that gives the pallet its strength.
Rule of thumb:
- 2‑inch‑thick reclaimed pallet boards can safely support ≈ 150 lb/ft² when laid flat on joists spaced 16” on center (typical for residential decks).
- Anything thinner than 1.5 inches should be avoided for the decking surface unless you add extra support (e.g., closer joist spacing or supplemental blocking).
If you plan to place hot tubs, large planters, or heavy outdoor furniture, you’ll need either thicker boards or a different material altogether.
3. Preparing Pallet Wood for Outdoor Use
3.1 Safety First – Inspect, Clean, and Treat
| Step | What to Do | Why It Matters |
|---|---|---|
| Inspect for Damage | Look for cracks, splits, rot, or insect tunnels. Discard any compromised boards. | Weak boards can fail under load. |
| Check for Nails & Staples | Use a nail puller or hammer to remove all fasteners. | Loose metal can puncture your deck surface later. |
| Identify Treatment | Look for stamps: HT (Heat Treated), MB (Methyl Bromide), KD (Kiln Dried). Avoid CC (Chemical Preservatives) and BCT (Boric Acid). | Some chemicals are unsafe for skin contact and can leach into soil. |
| Wash & Dry | Scrub with a stiff brush, then hose down. Let dry completely (at least 48 h). | Removes dirt, oil, and any pesticide residues. |
| Sand | Start with 80‑grit, finish with 120‑grit. | Smooths splinters and prepares the surface for stain or sealant. |
Pro tip: If you can’t locate a treatment stamp, treat the wood as if it’s chemically treated. You’ll want to seal it thoroughly and avoid using it for food‑preparation areas.
3.2 Strengthening the Deck Surface
- Lay Boards with the Grain Across Joists – This gives the board its maximum bending strength.
- Use “Double‑Layer” Decking – Place two 1‑inch boards on top of each other (or a 1‑inch board over a 2‑inch board) and fasten them to the joists. The sandwich effect dramatically improves stiffness.
- Add Blocking – Install 2×4 or 2×6 blocking between joists at 4‑foot intervals to reduce bounce and keep the boards from deflecting.
4. Fastening Pallet Deck Boards
Because pallet boards often have uneven edges, you’ll need a fastening system that tolerates a little movement and still provides a solid hold.
| Fastener Type | Recommended for Pallet Deck | Benefits |
|---|---|---|
| Stainless‑Steel Deck Screws (3”) | Yes (preferred) | Corrosion‑resistant, holds tightly, easy to remove. |
| Exterior‑Grade Deck Screws (galvanized) | Acceptable | Less expensive, but may rust over time in salty air. |
| Hidden Deck Clip System | Optional | Provides a clean look; clips accommodate irregular board thicknesses. |
| Nails (hot‑dipped galvanized) | Not recommended | Prone to loosening, can split softer wood. |
Installation tip: Pre‑drill all holes to avoid splitting, especially with pine. Space screws 12‑inch apart along the joist, staggered on each side to distribute load evenly.
5. Finishing – Protecting Your Pallet Deck
Even the toughest pine will warp if left exposed to rain and sun. A proper finish extends service life and keeps the deck looking intentional rather than “unfinished”.
| Finish | Application Steps | Lifespan (Typical) |
|---|---|---|
| Penetrating Exterior Wood Stain + Sealant | 1️⃣ Clean; 2️⃣ Apply stain (oil‑based) with a brush; 3️⃣ Follow with a clear sealer (polyurethane or marine varnish). | 3‑5 years before re‑application. |
| Deck Paint (Urethane‑Acrylic) | 1️⃣ Sand to smooth; 2️⃣ Prime with exterior primer; 3️⃣ Apply two coats of deck paint. | 5‑7 years; good for a uniform look. |
| Oil‑Based Deck Oil | 1️⃣ Clean; 2️⃣ Apply oil with a roller; 3️⃣ Wipe excess after 20 min. | 2‑3 years; enhances natural grain. |
| No Finish (Leave Natural) | 1️⃣ Sand to smooth; 2️⃣ Apply a spar varnish (if desired). | 1‑2 years; requires frequent maintenance. |
Best practice: Use a UV‑blocking sealant if you live in a sunny climate. Re‑apply every 12‑18 months to a high‑traffic deck, and every 24‑36 months to a lightly used area.
6. Cost Comparison – Pallet Deck vs. Conventional Decking
| Feature | Pallet Wood Deck (DIY) | Pressure‑Treated Lumber | Composite Decking |
|---|---|---|---|
| Material Cost (per sq ft) | $0.30 – $0.80* | $2.50 – $4.00 | $4.00 – $7.00 |
| Fasteners & Hardware | $0.20 – $0.35 | $0.25 – $0.40 | $0.30 – $0.45 |
| Finish (stain + sealer) | $0.35 – $0.50 | $0.30 – $0.45 | $0.40 – $0.60 |
| Total Approx. Cost | $0.85 – $1.65 | $3.05 – $4.85 | $4.70 – $7.60 |
| Life Expectancy (with proper maintenance) | 5‑10 years | 10‑15 years | 20‑30 years |
| Environmental Impact | Low (reclaimed) | Moderate (new wood, chemicals) | High (plastic resin) |
| Installation Difficulty | Moderate‑High (requires prep) | Easy‑Moderate | Easy‑Moderate |
*Cost assumes you obtain pallets for free or at a nominal price and that you have basic tools on hand. Labor is excluded; DIY labor is “free” for the homeowner but may be considerable for novice builders.
7. When Pallet Decking Makes Sense (and When It Doesn’t)
| Situation | Pallet Deck Viable? | Reason |
|---|---|---|
| Small, Low‑Traffic Patio (≤ 150 sq ft) | ✅ | Lower loads, aesthetic appeal shines. |
| Family‑Size Deck with Heavy Furniture | ❌ (unless you double‑layer and reinforce joists) | Structural demands exceed typical pallet capacity. |
| Coastal or High‑Humidity Area | ❌ (unless you use a marine‑grade sealant) | Salt and moisture accelerate rot in softwoods. |
| Budget‑Critical Renovation | ✅ | Massive savings on material; labor is the main cost. |
| DIY Project with Limited Tools | ❌ (or careful planning) | Removing nails, sanding, and leveling require power tools. |
8. Step‑by‑Step DIY Overview
- Plan & Design – Sketch your deck, determine dimensions, and calculate joist spacing.
- Source Pallets – Target pallets stamped HT (heat treated) or KD (kiln dried). Avoid chemically treated pallets.
- Dismantle – Use a crowbar or reciprocating saw to separate boards; remove all fasteners.
- Inspect & Sort – Separate boards by thickness (≥ 1.5 in) and condition.
- Treat & Dry – Clean, sand, and let the wood dry for at least 48 h.
- Build Frame – Install joists, add blocking, and verify levelness.
- Lay Deck Boards – Position boards perpendicular to joists, leave a ¼‑inch gap for drainage, fasten with stainless screws.
- Finish – Apply stain, oil, or paint per manufacturer’s instructions; seal edges and ends.
- Maintain – Sweep debris, re‑apply sealant annually, and inspect for rot or loose screws.
9. Frequently Asked Questions
Q1: Do I need a building permit to install a pallet deck?
A: Most municipalities require a permit for any permanent deck over 200 sq ft or above a certain height (typically 30 in). Check local codes; a small patio deck often qualifies as a “ground‑level” structure and may be exempt.
b) Q2: Can I use pallets that have the MB (Methyl Bromide) stamp?
A: MB indicates a chemical fumigant that can be hazardous. While the chemical dissipates over time, many DIYers choose to avoid MB pallets for outdoor furniture. If you must use them, seal the wood thoroughly and let it cure for several weeks before installing.
c) Q3: How often should I reseal a pallet deck?
A: In sunny, dry climates, reseal every 12 months. In damp or humid regions, aim for every 6‑9 months. Look for water beading on the surface; when it stops, it’s time to reapply.
d) Q4: Will pallet decking warp or cupping?
A: Yes, especially if the boards are thin or not properly acclimated. To minimize movement, store the boards in a covered area for at least 48 h before installation, keep them flat on the joists, and maintain a consistent seal.
e) Q5: Is it safe for children or pets?
A: Once all nails and staples are removed and the deck is sanded smooth, pallet wood is safe. However, the natural grain can be splintery, so a good finish (oil or sealant) is essential for a child‑friendly surface.
f) Q6: Can I install railing on a pallet deck?
A: Absolutely. Use the same joist layout as a standard deck. For added stability, consider a separate railing frame anchored directly to the joists rather than relying on the decking boards alone.
g) Q7: What tools do I need?
A: Reciprocating saw or circular saw, nail puller, 80/120‑grit sanders (or hand sander), drill with driver bits, stainless‑steel deck screws, and a brush/roller for staining.
h) Q8: How do I protect against insects?
A: Treat the wood with a borate-based insecticide before finishing, or choose pallets made of naturally decay‑resistant species (e.g., oak). Sealing the wood also creates a barrier that deters termites.
10. Bottom Line – Is Pallet Wood Right for Your Deck?
If you’re after a budget‑friendly, eco‑conscious, and rustic look, pallet wood can be a fantastic choice—provided you give it the proper preparation, reinforcement, and protection. Think of pallet decking as a project for the adventurous DIYer who doesn’t mind a little extra labor for a big savings payoff.
For high‑traffic, load‑heavy, or coastal decks, traditional pressure‑treated lumber or composite decking still reigns supreme. The key is matching the material to the intended use and the amount of maintenance you’re willing to commit to.
Ready to get started? Pull a few pallets from your local hardware store, gather a set of stainless screws, and let the transformation begin. In a few weekends you could have a unique, reclaimed deck that’s the envy of the neighborhood—without breaking the bank.
Quick Reference Checklist
- Identify wood species and treatment stamps.
- Remove all nails, staples, and broken boards.
- Clean, dry, and sand the wood.