Decking Made from Wooden Pallets: A Complete DIY Guide
If you’ve ever walked past a stack of discarded pallets and imagined a stylish outdoor deck sprouting from them, you’re not alone. Pallet‑derived decking has surged in popularity among budget‑conscious DIYers, eco‑enthusiasts, and anyone who loves a good “up‑cycle” project. In this post you’ll discover why pallets are a smart decking material, how to plan and build your own deck step‑by‑step, and what pitfalls to avoid so the finished surface looks polished, stays safe, and lasts for years.
Below you’ll find tables summarizing costs, material specs, and the pros/cons of pallet decking—plus a handy FAQ to answer the most common questions. Grab a coffee, fire up your spreadsheet, and let’s turn those wooden crates into a backyard masterpiece.
1. Why Choose Pallet Decking?
| Factor | Pallet Decking | Traditional Pressure‑Treated Wood | Composite Decking |
|---|---|---|---|
| Cost per sq ft | $2–$5 (often free) | $4–$6 | $8–$12 |
| Environmental impact | Up‑cycled, low‑carbon | Requires fresh timber & chemicals | Made from recycled plastics & wood fibers, but higher manufacturing energy |
| Weight | Light to moderate (depends on board thickness) | Moderate to heavy | Light to moderate |
| Installation difficulty | Moderate (needs disassembly, sanding) | Easy (pre‑cut boards) | Easy (click‑lock systems) |
| Durability (if maintained) | 5–10 yr with proper sealant | 10–15 yr (treated) | 25+ yr (warranty) |
| Aesthetic flexibility | Rustic, customizable | Classic, uniform | Modern, uniform |
Bottom line: Pallet decking is the most economical and environmentally friendly option, provided you’re willing to invest a little extra time in preparation and finishing.
1.1. Where to Find Pallets
| Source | Typical Cost | Tips for Selecting |
|---|---|---|
| Local warehouses / retail stores | Free (often) | Ask a manager; look for pallets stamped “HT” (heat‑treated) – safer than chemically treated “MB”. |
| Construction sites (with permission) | Free–$10/pallet | Arrive early, bring a dolly. |
| Craigslist / Facebook Marketplace | $5‑$15/pallet | Verify condition in photos; avoid pallets with broken boards or heavy staining. |
| Re‑use centers / Habitat for Humanity ReStore | $10‑$30/pallet | Usually inspected, may include a small fee. |
Key rule: Never use pallets marked “MB” (Methyl Bromide) or any that have obvious signs of rot, insect damage, or chemicals (e.g., oil stains). Heat‑treated (“HT”) pallets are safe for outdoor use.
2. Planning Your Pallet Deck
2.1. Measure & Sketch
- Determine the deck footprint – measure length, width, and any protrusions (e.g., steps, railings).
- Draw a simple plan (hand‑sketch or free CAD tool). Mark where support posts, joists, and ledger boards will go.
- Calculate material quantities using the formulas below:
Deck Area (sq ft) = Length ft × Width ft
Number of Pallet Deck Boards = (Deck Area ÷ Board Surface Area) × 1.1 (10 % waste factor)
Most standard pallets measure 48 in × 40 in (4 ft × 3.33 ft). When you split a pallet into individual 1‑in‑thick boards, each board typically yields about 4 ft × 1 ft of surface.
| Deck size | Approx. # of pallets needed* |
|---|---|
| 8 ft × 8 ft (64 sq ft) | 20–25 |
| 10 ft × 12 ft (120 sq ft) | 40–45 |
| 12 ft × 16 ft (192 sq ft) | 80–90 |
*Assumes 1‑in‑thick boards, 10 % waste, and that you’ll discard some pallet frames.
2.2. Tools & Materials Checklist
| Tool | Purpose |
|---|---|
| Circular saw or table saw | Cutting boards to length |
| Power drill + screwdriver bits | Pre‑drilling & assembling |
| Belt sander or orbital sander | Smoothing rough surfaces |
| Angle grinder (optional) | Removing nails, shaping ends |
| Tape measure & carpenter’s square | Accurate layout |
| Level & string line | Ensure a flat surface |
| Safety gear (gloves, goggles, ear protection) | Personal protection |
| Material | Qty (per 100 sq ft) |
|---|---|
| Pallet boards (1‑in thick) | ~120 pcs (approx. 40 pallets) |
| Deck screws (galvanized, 2½”) | 5‑6 lb |
| Joist lumber (2×6, pressure‑treated) | 20 ft |
| Concrete mix (for footings) | 1 bag per post |
| Sealant/Exterior wood oil | 1 gal |
| Weed‑membrane (optional) | 1 roll (100 sq ft) |
| Deck paint/stain (optional) | 1 gal |
3. Step‑by‑Step Construction
Below is a practical workflow that balances speed with a quality finish. Feel free to adapt the steps to your specific site conditions.
| Step | Action | Details |
|---|---|---|
| 1 | Secure pallets | Collect pallets, stack them upright, and secure with zip‑ties. Keep the “HT” stamps visible for future reference. |
| 2 | Disassemble | Using a pry bar and hammer, carefully remove all nails. A nail‑puller or angle grinder can speed this up. |
| 3 | Cut boards | Cut each pallet plank to your desired deck width (typically 6–8 in). Keep the longer side parallel to the deck’s length for a seamless look. |
| 4 | Sand | Run a belt sander over each board to eliminate splinters and rough edges. Finish with a fine‑grit orbital sander for a smooth surface. |
| 5 | Treat | Apply a wood preservative or exterior oil to protect against moisture and UV. Let dry per manufacturer’s instructions (usually 24 hrs). |
| 6 | Lay out footings | Mark post locations (typically 4‑ft apart). Dig 12‑in‑deep holes, add 2 in of gravel, pour concrete, and embed a metal post anchor. |
| 7 | Install joists | Attach 2×6 joists to the ledger board (or a concrete beam) with galvanized joist hangers. Space joists 12‑in apart for a sturdy base. |
| 8 | Fasten deck boards | Starting at one end, lay the pallet boards perpendicular to joists. Pre‑drill ¾‑in pilot holes to avoid splitting, then screw each board down with two screws per joist. |
| 9 | Add railing (optional) | Use leftover pallet material or purchase a simple metal railing kit. Secure posts to the joists with post‑base brackets. |
| 10 | Finish | Apply a second coat of sealant or a deck stain for color. Replace any missing screws, and clean the deck surface. |
3.1. Tips for a Professional Look
- Stagger board joints: Like brickwork, offset the seams every row to improve stability and hide any small gaps.
- Maintain a ¼‑in gap between boards: This allows water drainage and prevents warping. Use spacers while screwing down.
- Avoid “pallet‑to‑pallet” nail holes: Pre‑drilling on the underside of joists will give a cleaner appearance on the top side.
- Seal all ends: Brush sealant into any cut ends of boards; untreated ends absorb moisture faster and can cause splitting.
4. Maintenance & Longevity
Even though pallets are a budget‑friendly option, they require a bit more upkeep than commercial decking. Follow this schedule to keep your deck looking fresh:
| Frequency | Maintenance Task |
|---|---|
| Monthly | Sweep debris, inspect for loose screws, wipe down with a damp cloth. |
| Seasonally (Spring/Fall) | Re‑apply a light coat of exterior oil or stain; check for signs of rot or insect activity. |
| Annually | Power‑wash (low pressure) to remove mildew, then reseal. Replace any cracked or severely warped boards. |
| Every 2‑3 years | Full resurfacing: sand lightly, then apply a penetrating preservative. |
Pro tip: If you live in a high‑humidity area, consider installing a thin layer of landscape fabric beneath the deck boards (between joists and the ground). This barrier reduces moisture wicking from the soil and extends the life of the wood.
5. Cost Breakdown (Sample 8 ft × 8 ft Deck)
| Item | Quantity | Unit Cost | Total |
|---|---|---|---|
| Pallet boards (1‑in) | 120 pcs | $0.75 each (free pallets, only labor) | $0 (material) |
| Joist lumber (2×6) | 20 ft | $3.00/ft | $60 |
| Galvanized deck screws | 5 lb | $0.30/oz | $24 |
| Concrete mix (footings) | 4 bags | $5.00/bag | $20 |
| Exterior wood oil | 1 gal | $30.00 | $30 |
| Tools (rental) | — | — | $50* |
| Subtotal | — | — | $184 |
| Labor (DIY) | — | — | Your time! |
*Tool rental includes a portable belt sander and a power drill. If you already own the tools, the cost drops to under $150—a fraction of the $800‑$1,200 price tag of a comparable commercially‑built deck.
6. Frequently Asked Questions
Q1: Are pallet decks safe for children and pets?
Answer: Yes, provided you sand all surfaces smooth, remove every nail, and use non‑toxic sealants. Regularly check for splinters or loose boards.
Q2: How do I know if a pallet is chemically treated?
Answer: Look for the three‑letter stamp on the pallet’s side. “HT” = heat‑treated (safe). “MB” = methyl bromide (avoid). If no stamp is visible, assume it may have been exposed to chemicals and choose a different source.
Q3: Can I use pallet decking for a raised garden bed?
Answer: Absolutely! Pallet boards are ideal for garden borders. Just line the interior with landscape fabric to keep soil from contacting the wood directly, and treat the wood with a safe, food‑grade sealant.
Q4: How much weight can a pallet deck support?
Answer: When built with proper joist spacing (12 in) and 2×6 pressure‑treated joists, a pallet deck can safely hold typical residential loads (≈40 psf). For heavy equipment (e.g., a hot tub), reinforce with additional joists or use thicker boards.
Q5: Do I need a building permit?
Answer: Permit requirements vary by municipality and deck size. Decks under 200 sq ft often qualify for a permit exemption, but always check with your local building department before you start.
Q6: What’s the best sealant for pallet decks?
Answer: A high‑quality exterior oil (e.g., tung oil blend) or a penetrating water‑repellent preservative works best. For a colored finish, choose a semi‑transparent deck stain that still lets the wood grain show.
Q7: How can I prevent warping?
Answer: Keep the boards flat during installation, maintain the ¼‑in gap for drainage, and apply sealant on all faces (top, bottom, and ends). Avoid direct contact with soil—use a sub‑frame or landscape fabric.
7. Final Thoughts
Building a deck from wooden pallets isn’t just a thrifty weekend project; it’s a chance to reimagine waste as a functional design element. With a modest investment of time, a few basic tools, and the right preparation, you’ll end up with a warm, rustic surface that invites gatherings, outdoor meals, or simply a quiet spot to enjoy the sunset.
Remember: the secret to a beautiful pallet deck lies in preparation—select clean heat‑treated pallets, sand thoroughly, and seal every surface. Once those fundamentals are in place, the construction process is straightforward, and the payoff is a deck that feels both homemade and professional.
Ready to roll up your sleeves? Grab those pallets, sketch out your plan, and start turning discarded wood into a standout feature of your garden. Happy building!