Can You Use Wooden Pallets for Decking?
An In‑Depth Guide to Turning Free‑Standing Pallets Into a Beautiful, Functional Outdoor Floor
When you walk past a warehouse or a big‑box store you’ll see rows of wooden pallets stacked like a miniature skyline. To the untrained eye they’re just cheap transport containers, but to a DIY‑savvy homeowner they can be a treasure trove of budget‑friendly decking material.
If you’ve ever wondered, “Can I use wooden pallets for decking?” the answer is a qualified yes—provided you follow a few critical steps and keep safety front‑and‑center. In this guide you’ll learn everything you need to know to turn those often‑discarded pallets into a sturdy, stylish deck that can hold a weekend BBQ, a hammock, or a set of outdoor furniture.
1. Why Consider Pallet Decking?
| Benefit | What It Means for You |
|---|---|
| Cost‑Effective | Pallets are often free or cost a few dollars each. Compared with commercial decking (which can run $20‑$50 per square foot), pallets can save you hundreds or even thousands. |
| Eco‑Friendly | Re‑using pallets keeps wood out of landfills and reduces the demand for new lumber. |
| Customizable | Pallet boards come in a range of dimensions (typically 48”×40”). You can cut, sand, and arrange them to match any design aesthetic. |
| Quick to Source | Many retailers, construction sites, and recycling centers will give them away. A simple phone call can secure a whole stack. |
| Rustic Charm | The weathered, reclaimed look works perfectly for farmhouse, industrial, or coastal‑vibe decks. |
The Trade‑Offs
| Potential Drawback | How to Mitigate It |
|---|---|
| Variable Quality | Inspect each pallet for rot, cracks, or broken boards before buying. |
| Chemicals & Treatments | Choose pallets marked “HT” (heat‑treated) rather than “KD” (kiln‑dried) or “MB” (methyl bromide). Heat‑treated pallets are safer for outdoor use. |
| Uneven Surfaces | Sand and plane boards, then add a level sub‑frame to ensure a flat deck. |
| Limited Lifespan | Treat the wood with a quality sealant or decking oil and plan for a refresh every 3‑5 years. |
2. Planning Your Pallet Deck
2.1. Determine the Deck Size
Before you start hunting for pallets, sketch a simple plan. Measure the area you want to cover and calculate the number of pallets you’ll need.
| Deck Area | Pallet Footprint (48”×40” = 13.3 ft²) | Pallets Required (rounded up) |
|---|---|---|
| 8 ft × 10 ft (80 ft²) | 13.3 ft² | 7 |
| 12 ft × 12 ft (144 ft²) | 13.3 ft² | 11 |
| 16 ft × 20 ft (320 ft²) | 13.3 ft² | 25 |
Add 10‑15 % extra for waste, cuts, and damaged boards.
2.2. Check Local Building Codes
Even though pallet decks are often considered “DIY garden furniture,” many municipalities require a permanent deck to meet structural standards—especially if it’s higher than 30 inches off the ground or will support a permanent railing. Call your local building department to learn about:
- Minimum joist spacing (usually 16” on center)
- Required footings or concrete piers
- Deck height restrictions
If the code is strict, you may need to mount the pallets on a proper sub‑frame rather than laying them directly on the ground.
2.3. Choose the Right Pallets
Look for pallets that meet these criteria:
| Feature | Why It Matters |
|---|---|
| Heat‑treated (HT) | No hazardous chemicals; safe for outdoor exposure |
| Solid, unbroken boards | Increases structural integrity |
| Uniform size | Simplifies layout and reduces waste |
| Minimal nails or staples | Easier to disassemble for repairs |
If you see the “HT” stamp, you’re good to go. Otherwise, treat the pallet as a raw material and be prepared for extra cleaning.
3. Preparing the Pallets
3.1. Clean & Disinfect
- Remove debris – Shake out loose dirt, leaves, and nails.
- Wash – Use a garden hose and mild detergent; scrub with a stiff brush.
- Disinfect – Mix one part bleach to nine parts water, spray the surface, and let it sit 10 minutes. Rinse thoroughly.
- Dry – Let the pallets air‑dry for 24‑48 hours in a sunny, well‑ventilated area.
3.2. Strip & Re‑orient
- Nail removal – Use a flat‑head screwdriver or a nail puller to extract protruding nails.
- Board orientation – For added strength, place the long grain of each board parallel to the joists (i.e., perpendicular to the deck’s span).
3.3. Sand & Shape
- Sanding – Run a belt sander or orbital sander over each board to eliminate splinters and rough patches. Start with 80‑grit, finish with 120‑grit.
- Cutting – Use a circular saw or miter saw to trim boards to the desired length. Remember to leave a 1/8‑inch gap between boards for drainage and expansion.
3.4. Seal & Protect
Apply a decking oil, spar urethane, or a penetrating water‑repellent. Follow the manufacturer’s instructions—usually two coats are enough. This step dramatically extends the life of pallet wood and keeps it from absorbing moisture.
4. Building the Deck – Step‑by‑Step
Below is a streamlined sequence that works for most ground‑level decks (0‑6 ft high). If your deck is higher, replace the concrete footings with a proper stilt system.
| Step | What You Do | Key Tips |
|---|---|---|
| 1. Lay the Foundation | Place pressure‑treated 4×4 posts on compacted gravel or concrete piers. Space them 4‑ft apart (or per joist design). | Use a level; ensure posts are plumb. |
| 2. Install Joists | Attach 2×6 or 2×8 joists to the posts with galvanized joist hangers. Space joists 16” on center. | Pre‑drill pilot holes to avoid splitting. |
| 3. Add a Sub‑Floor (Optional) | Lay ½‑inch plywood on top of joists, screw every 6‑8 inches. This creates a smooth base and prevents sagging. | If you skip sub‑floor, attach pallets directly to joists with decking screws. |
| 4. Position Pallet Boards | Lay each pallet board (or individual stripped boards) perpendicular to joists. Stagger joints by at least 12 inches for strength. | Use a rubber mallet to tap boards into place without damaging them. |
| 5. Secure Boards | Drive galvanized decking screws (2½‑3 in) through each board into the joist below. Space screws every 12‑16 inches. | Countersink screws slightly to avoid a snaggy surface. |
| 6. Trim & Finish Edges | Cut any over‑hang with a circular saw; install a border board or trim to hide raw edges. | Apply a final coat of sealant to the cut ends. |
| 7. Add Railings & Stairs (if needed) | Build a simple post‑and‑rail system using the same pallet wood for visual continuity. | Use stainless steel hardware for rust resistance. |
| 8. Clean & Inspect | Sweep away debris, check for loose screws, and test the deck’s stability with a weight load. | Walk the deck with a 30‑lb bag of sand to simulate real use. |
4.1. Cost Snapshot
| Item | Average Cost (USD) |
|---|---|
| Pallets (HT, free or $5 each) | $0‑$150 (depends on quantity) |
| Pressure‑treated 4×4 posts (8‑ft) | $10 each |
| Joist hangers (galvanized) | $0.80 each |
| 2×6 or 2×8 lumber (joists) | $2‑$4 per linear foot |
| Galvanized decking screws (5‑lb box) | $25 |
| Sealant / decking oil (1‑gal) | $30‑$45 |
| Total for a 12 ft × 12 ft deck | ≈ $550‑$800 (vs. $1,600‑$2,400 for commercial decking) |
5. Maintenance & Longevity
A pallet deck can last 5‑10 years with proper care. Here’s a quick maintenance schedule you can follow:
| Frequency | Task |
|---|---|
| Monthly | Sweep leaves, debris, and dirt to prevent moisture retention. |
| Quarterly | Inspect for loose screws, splintered boards, or signs of rot. Tighten or replace as needed. |
| Annually (Spring) | Power‑wash gently (use low pressure) and reapply a coat of sealant or decking oil. |
| Every 3‑5 Years | Perform a thorough sand‑and‑re‑seal, especially if the deck sees heavy foot traffic or exposure to harsh weather. |
If you notice soft wood, deep cracks, or persistent water pooling, replace the affected boards promptly. Swapping out a single pallet board is straightforward—just unscrew, remove, and slide a new one into place.
6. Design Ideas to Inspire You
- Café‑Style Pergola – Combine pallet decking with a simple pergola made from reclaimed lumber. Add string lights for ambiance.
- Multi‑Level Platform – Stack pallets at different heights to create a tiered lounge area. Use outdoor cushions and a low coffee table.
- Integrated Planters – Build low pallet boxes at the deck edges and fill with herbs or succulents. The “green border” softens the look.
- Stenciled Patterns – After sanding, use a stencil and outdoor paint to add geometric or floral motifs to selected boards.
- Floating Deck – Elevate the deck 6‑12 inches on discreet concrete footings; this gives a modern “floating” appearance while allowing airflow underneath.
7. Frequently Asked Questions (FAQ)
Q1. Are pallet decks legal in most cities?
Most municipalities treat a pallet deck as a “DIY garden structure” if it’s under 30 inches high and not permanently attached to a building. Always verify local building codes before you start.
Q2. Do I need to treat the pallets for pests?
If you use heat‑treated pallets, they’re already processed to kill insects. However, a sealant or decking oil creates a barrier that further discourages beetles and termites.
Q3. Can I use pallets that have the “KB” (kiln‑dried) stamp?
Kiln‑dried pallets may have been treated with chemicals that aren’t safe for outdoor, skin‑contact applications. Stick with “HT” pallets for the safest option.
Q4. How many pallets will I need for a 10 ft × 15 ft deck?
Each pallet covers ~13.3 ft². For 150 ft² you’d need about 12 pallets (allowing for cuts and waste). Add a few extra for replacement boards.
Q5. Will the deck be level if the ground is uneven?
No. The underlying ground must be prepared—either by compacting a gravel base and using adjustable footings, or by building a level sub‑frame. Pallet boards themselves can’t compensate for slope.
Q6. What type of screws should I use?
Use galvanized or stainless‑steel decking screws to resist rust. Avoid standard steel screws as they will corrode quickly.
Q7. Can I paint the pallet deck?
Yes, but it’s best to use a high‑quality exterior paint designed for wood. A primer that blocks moisture is essential. Paint may need refreshing every 2‑3 years.
Q8. How do I handle gaps between boards?
Leave a 1/8‑ to 1/4‑inch gap when installing boards. This allows water to drain and wood to expand/contract with temperature changes.
Q9. Is a sub‑floor necessary?
For a ground‑level deck, a sub‑floor isn’t mandatory but adds rigidity and smooths out any minor imperfections in the joist layout. It also makes future board replacement easier.
Q10. What’s the best way to secure the deck against wind?
Add deck brackets that tie the joist framework to the underlying footings. If you’re building a raised deck, consider diagonal bracing between joists.
8. Bottom Line: Should You Build a Pallet Deck?
The short answer: Yes—if you’re comfortable with a hands‑on project and willing to invest a few hours in preparation, pallet decking can be an affordable, attractive, and environmentally friendly alternative to store‑bought decking.
- Budget – You can create a 12 ft × 12 ft deck for under $800, a fraction of the cost of composite or premium hardwood decks.
- Skill Level – Basic carpentry (cutting, sanding, screwing) and a willingness to follow safety guidelines are all that’s required.
- Durability – With proper sealing and routine maintenance, pallet decks hold up well for several years, especially in moderate climates.
- Aesthetic Flexibility – From rustic farmhouse to sleek modern, the look can be tailored with paint, stains, lighting, and complementary reclaimed furniture.
If you’re ready to turn those overlooked pallets into a functional outdoor oasis, gather a few supplies, follow the steps outlined here, and enjoy the satisfaction of building something beautiful from something that would otherwise be thrown away. Happy decking!