Decking From Pallet Wood: A Hands‑On Guide for the DIY‑Enthusiast
You’ve spotted a stack of discarded pallets in the back of a warehouse, or perhaps you’ve already collected a few for a weekend project. Instead of tossing them aside, why not transform that rugged, low‑cost material into a beautiful, functional deck? Below is a step‑by‑step blueprint, complete with tips, tools, cost estimates, and a handy FAQ, so you can confidently turn pallet wood into a stunning outdoor surface.
Pallets are often free or very cheap, especially if you source them from local businesses that consider them waste.
Eco‑Friendly
Re‑using pallets diverts wood from landfills and reduces demand for newly milled lumber, lowering your carbon footprint.
Versatility
Pallet boards vary in length, width, and thickness, giving you a wide palette of design possibilities.
DIY Appeal
The rustic aesthetic of reclaimed wood adds character and makes a personal statement about sustainability.
Bottom line: If you have a modest budget, a love for up‑cycling, and a willingness to put in a bit of elbow grease, pallet decking checks all the boxes.
2. Planning Your Deck – What to Consider Before You Cut the First Board
Location & Sun Exposure – Decks that sit in full sun need wood that can tolerate UV‑induced fading.
Load‑Bearing Requirements – A typical residential deck must support 40–60 lb/ft² (live load). Pallet boards are usually ¾‑inch thick, so you’ll need a sturdy sub‑frame with adequate joists and support beams.
Local Building Codes – Some municipalities require a permit for decks larger than a certain size (often 200 sq ft). Verify clearance, railing height, and footing depth before you start.
Pallet Condition – Look for pallets stamped with “HT” (heat‑treated) rather than “MB” (methyl bromide) or “DP” (depersonalized). Heat‑treated pallets are safer for outdoor use and free from harmful chemicals.
Wood Quality – Avoid pallets with splintered, rot‑infested, or insect‑eaten boards. The best pallet wood will be relatively straight, free of cracks, and have a uniform grain.
3. Tools & Materials Checklist
Tool / Material
Purpose
Suggested Specs
Circular saw or miter saw
Cutting boards to length
7‑1⁄4″ blade for clean cuts
Power sander (orbital)
Smoothing rough surfaces
120‑grit sandpaper (finish with 220‑grit)
Drill & impact driver
Pre‑drilling and driving fasteners
1/8‑in. drill bit for pilot holes
Deck screws (galvanized or stainless)
Secure boards to joists
2½‑in. or 3‑in. for ¾‑in. thickness
Joist hangers & corrosion‑resistant brackets
Reinforce framing
Hot‑dip galvanized
Wood preservative / exterior stain
Protect against moisture, UV
Oil‑based or water‑based, as preferred
Safety gear (gloves, goggles, dust mask)
Personal protection
N/A
Measuring tape, carpenter’s square, level
Accuracy
N/A
4. Step‑by‑Step Build Process
Step 1 – Harvest & Sort the Pallets
Collect at least 20–30 pallets for a modest 8 × 12‑ft deck (≈ 96 sq ft).
Disassemble using a pry bar and hammer—remove the nails carefully; a nail puller or reciprocating saw can speed this up.
Sort the planks by length, width, and condition. Keep a “good” pile for the decking surface and a “rough” pile for sub‑framing or under‑deck storage.
Step 2 – Prepare the Boards
Remove all nails and staples with a magnetic nail puller or a pair of pliers.
Cut to size: Standard deck boards are 5.5–6 in. wide. Trim longer pallets to your desired deck width (e.g., 6‑ft or 8‑ft sections).
Sand each face: Start with 120‑grit to eliminate splinters, then finish with 220‑grit for a smooth surface.
Treat the wood: Apply a penetrating wood preservative, then after it dries, coat with exterior stain or clear polyurethane. This protects against rain, sun, and insects.
Mark the footprint on the ground with spray paint or string.
Excavate to a depth of 6‑8 in. for footings; add a compacted gravel base.
Install concrete footings or pre‑cast deck blocks at each joist intersection (typically 16‑in. on center).
Attach joists (2×6 or 2×8 pressure‑treated lumber) to the footings using joist hangers. Keep spacing at 16‑in. OC for a ¾‑in. deck board.
Step 4 – Install the Decking Boards
Dry‑fit the pallet boards first: Lay them across the joists and check for gaps. Trim any over‑hang.
Pre‑drill pilot holes ½‑in. from the board edge to avoid splitting.
Secure with 2½‑in. stainless‑steel decking screws, spacing every 12‑in. along each joist. A hidden‑fastener system (e.g., hidden clips) can give a cleaner look but isn’t necessary for a budget build.
Step 5 – Finishing Touches
Task
Why It Matters
Apply a second coat of stain
Ensures even color and deeper penetration, extending lifespan.
Add a perimeter railing (optional)
Safety and aesthetic. Use reclaimed pallet wood or metal balusters.
Install a sealant on cut ends
Prevents moisture infiltration at board ends, reducing rot.
Lay down outdoor rugs or planters
Adds comfort and decor while protecting the deck from foot traffic wear.
5. Maintenance – Keep Your Pallet Deck Looking Fresh
Action
Frequency
Tips
Sweep debris
Weekly
Prevents moisture retention and mold growth.
Clean with mild soap & water
Monthly (or after heavy rain)
Use a soft bristle brush; avoid pressure washers that can lift the wood fibers.
Re‑apply sealant or stain
Every 2‑3 years (depending on exposure)
Light‑sand the surface (220‑grit) before re‑coating for best adhesion.
Inspect for loose screws or rot
Annually
Tighten any loose hardware and replace compromised boards promptly.
6. Cost Comparison – Pallet Deck vs. Conventional Deck
Item
Pallet Deck (estimated)
Standard Pressure‑Treated Deck
Materials (wood, fasteners, stain)
$250–$400
$900–$1,500
Tools (if you already own)
$0 (reuse)
$0 (reuse)
Labor (DIY)
Your time
Your time
Disposal/haul‑away
Minimal (reuse)
May cost $150–$300
Total
≈ $250–$400
≈ $1,050–$1,800
Bottom line: Pallet decking can be up to 75 % cheaper while delivering a unique rustic charm.
7. Common Pitfalls & How to Avoid Them
Problem
Cause
Solution
Boards warp after installation
Inadequate drying before staining
Air‑dry pallet boards for at least 7 days in a shaded, well‑ventilated area.
Splintered surface
Insufficient sanding or using rough‑cut pallets
Sand both faces thoroughly and apply a protective coating.
Fasteners rust quickly
Using plain steel screws
Opt for galvanized or stainless‑steel screws.
Deck feels “spongy”
Joist spacing too wide for ¾‑in. boards
Keep joist spacing at 16‑in. on center or use thicker boards (1‑in.) for larger spans.
Unexpected chemical exposure
Pallets treated with methyl bromide (MB)
Only accept pallets marked “HT” (heat‑treated) or “CP” (chemically processed), and treat them with a sealant before use.
8. FAQ – Quick Answers to Your Most Pressing Questions
Question
Answer
Do I need a building permit?
Most municipalities require a permit for decks larger than 200 sq ft or for any raised platform. Check with your local building department before you start.
Is pallet wood safe for outdoor use?
Yes, as long as you use heat‑treated pallets (marked “HT”). Avoid pallets treated with chemicals like methyl bromide (MB). After cleaning, sanding, and sealing, they are safe for outdoor exposure.
How long will a pallet deck last?
With proper treatment and regular maintenance, a pallet deck can last 10–15 years, comparable to a conventional pressure‑treated deck.
Can I use regular deck screws?
Opt for stainless‑steel or hot‑dip galvanized screws to resist corrosion. Regular steel screws will rust and stain the wood over time.
What’s the best way to attach the boards to avoid visible screw heads?
Use a hidden‑fastener system (e.g., deck clips) or countersink the screws and fill the holes with wood filler before staining.
Do I need to apply a water‑repellent sealer on the ends of the boards?
Absolutely. End‑grain absorbs moisture quickly, so applying a brush‑on sealer on cut ends dramatically reduces rot risk.
Can I paint over the pallet wood instead of staining?
Yes, but you must first apply a primer designed for exterior wood, then use a high‑quality exterior paint. Stain generally showcases the reclaimed grain more naturally.
What if the pallets have nails still embedded?
Use a nail puller, a reciprocating saw with a metal‑cutting blade, or a pneumatic nail gun to extract them. Leaving nails can damage the deck surface and pose a safety hazard.
9. Final Thoughts – Your Sustainable Outdoor Retreat Awaits
You now have a complete roadmap to turn discarded pallets into a functional, eye‑catching deck. The process blends creativity with practicality: you’ll learn to assess wood quality, master basic carpentry techniques, and finish your project with a durable, eco‑friendly coating.
Remember: the charm of pallet decking lies not only in its low cost but also in the story each board tells. By investing a little extra time in preparation—cleaning, sanding, and sealing—you’ll enjoy a deck that ages gracefully, gaining character as the years go by.
So gather those pallets, roll up your sleeves, and start building the outdoor sanctuary you’ve been dreaming about. Your backyard (and the planet) will thank you.
