Repair. Don't Replace.
Most 'broken' pallets need 1–3 board replacements. We fix them in minutes at a fraction of replacement cost.
Broken deck boards
Missing or split blocks
Damaged stringers
Loose nails or fasteners
Partial rebuild
Full recondition to Grade A
Average savings vs. purchasing new pallets
Based on Grade A recondition vs. new GMA pallet prices
We Repair At Your Facility
For large volumes (500+ pallets), we can send a crew to your facility with tools and materials. Minimizes transport cost and keeps your operation running.
Bring Them to Our Yard
Drop off your damaged pallets at our yard in San Diego. Turnaround is typically 3–7 business days depending on volume and damage level.
Every Type of Pallet Damage, Fixed Right
Pallet damage comes in many forms, but the solution almost never requires buying a new pallet. Our repair crews handle everything from a single cracked board to a full structural rebuild. Here is a detailed look at every repair type we perform.
Deck Board Replacement
Cracked, split, or missing deck boards are the most common pallet damage. A forklift tine punches through a top board, a heavy load cracks a bottom board, or weathering causes splits along the grain. We remove the damaged board using pneumatic pry tools that preserve the surrounding structure, then nail a replacement board of matching thickness and width using ring-shank coil nails for superior holding power.
Our replacement boards are sourced from our own dismantling operation and from kiln-dried Southern Yellow Pine and hardwood lumber suppliers. Every board meets NWPCA minimum thickness standards: 5/8-inch minimum for standard GMA deck boards. We stock common widths (3.5-inch, 5.5-inch, and 7.25-inch) for immediate availability.
Stringer Repair & Reinforcement
Stringers are the long horizontal members that run the length of a stringer-style pallet. When a stringer cracks or splits, the pallet loses its load-bearing capacity and becomes unsafe for racking. We repair cracked stringers using companion stringers, which are shorter boards nailed alongside the damaged section to restore structural integrity.
For stringers with notch damage (the cutouts where forklift tines enter), we apply a notch-area reinforcement using a hardwood plug or companion board. If the stringer is broken completely through, we replace the entire stringer by removing the deck boards above and below, sliding out the damaged stringer, inserting a new one, and re-nailing the assembly. This is our most labor-intensive repair but still costs less than half the price of a new pallet.
Block Replacement
Block-style pallets (also called four-way entry pallets) use blocks of wood instead of stringers to support the deck. Blocks crack, chip, or split under heavy loads or from repeated forklift impacts. A missing or damaged block compromises the entire pallet because each block bears a proportional share of the load.
We replace blocks by removing the fasteners holding the damaged block, extracting it, and nailing a new hardwood block of identical dimensions. We keep blocks in all standard sizes: 3.5x3.5x3.5 inch (used in CHEP-style pallets), 4x4x6 inch (common in GMA block pallets), and custom dimensions for specialty pallets. Block replacement restores full four-way forklift entry and racking capability.
Re-nailing & Fastener Tightening
Over time, nail joints loosen. Boards shift, pallets become wobbly, and load stability decreases. Re-nailing is the simplest and cheapest repair we perform. Using pneumatic coil nailers with ring-shank nails (which provide 3x the holding power of smooth-shank nails), we re-fasten every loose joint on the pallet.
We also address protruding nails, which are a safety hazard for warehouse workers and can damage products. Every nail is driven flush or countersunk slightly below the board surface. For pallets that will contact sensitive goods (electronics, food packaging), we inspect for and remove any nail points protruding through the opposite side of the board.
Repair vs. Replace: The Real Numbers
The math is straightforward. In almost every scenario, repairing a pallet costs a fraction of replacing it with a new one. Here is a side-by-side comparison for the most common damage scenarios on a standard 48x40 GMA pallet.
| Damage Scenario | Repair Cost | New Pallet Cost | You Save |
|---|---|---|---|
| 1 cracked deck board | $1.50 | $14-$18 | 87-92% |
| 2 boards + re-nailing | $3.80 | $14-$18 | 73-79% |
| 1 cracked stringer + 1 board | $5.50 | $14-$18 | 61-69% |
| 3 deck boards + 2 blocks | $8.50 | $14-$18 | 39-53% |
| Full recondition to Grade A | $8.00-$10.00 | $14-$18 | 29-44% |
| Rebuild (50%+ components replaced) | $10.00-$12.00 | $14-$18 | 17-33% |
When Does Replacement Make Sense?
We are in the repair business, but we are honest about when repair is not the right call. If more than 50% of the pallet components need replacement, the repair cost approaches the cost of a new pallet and you lose the benefit. If the pallet has mold, chemical contamination, or insect damage, it should be recycled rather than repaired. And if you need ISPM 15 certified pallets and your existing inventory is untreated, it is often more cost-effective to buy new heat-treated pallets than to repair old ones and then treat them. We will always give you an honest recommendation.
Repair Quality Standards
A repaired pallet should perform identically to its original specification. We follow documented quality standards on every repair to ensure structural integrity and consistent results.
Grade A Standard
- All boards intact with no cracks exceeding 1/4 of board width
- All fasteners driven flush, no protruding nail points
- Stringers or blocks solid with no splits through load-bearing areas
- Pallet sits flat on all 3 stringer contact points (no wobble)
- No mold, staining, or contamination visible on deck surfaces
- Suitable for racking, automated handling, and food-adjacent use
Grade B Standard
- Minor cosmetic damage allowed: surface stains, small chips, weathering
- All boards structurally sound and properly fastened
- One companion stringer repair allowed per pallet
- Pallet must support rated load without deflection beyond NWPCA limits
- Suitable for general warehouse use and ground-level stacking
- Not recommended for automated AS/RS systems or clean environments
Grade C Standard
- Functional for single-use or one-way shipping applications
- Up to 2 companion stringer repairs allowed
- Up to 3 replaced deck boards allowed
- Must support minimum 2,000 lbs evenly distributed load
- Visual appearance is secondary to structural function
- Lowest cost option, ideal for export or one-trip domestic freight
Turnaround Times & Capacity
How fast your pallets come back depends on volume, damage severity, and whether we work on-site at your facility or at our yard. Here is what to expect.
At Our Yard
On-Site at Your Facility
For volumes of 500+ pallets, on-site repair is often faster and cheaper because it eliminates the transportation step. Our mobile repair crew arrives at your facility with all tools, nails, and replacement boards. Here is typical on-site production:
On-site minimum: 500 pallets. Crew available Monday through Friday, 7 AM to 3:30 PM. Multiple crews can be deployed for projects exceeding 2,000 pallets.
Rush Repair Service
Need pallets repaired urgently? Our rush service moves your order to the front of the queue. Rush repairs on volumes under 200 pallets can be completed in 24 hours. Rush orders carry a 25% surcharge over standard repair pricing. Contact us by 8 AM and your repaired pallets can be ready for pickup or delivery the next morning.
Before & After: Real Repair Examples
These are real examples from our repair line, showing the kind of damage we fix daily and the result after our crews are done.
Forklift Punch-Through on 48x40 Stringer Pallet
A forklift tine punched through two top deck boards and cracked the center stringer at the notch point. The pallet was pulled from service and marked for disposal by the warehouse team.
We replaced both top deck boards with 5/8-inch kiln-dried SYP boards and applied a 24-inch companion stringer alongside the cracked center stringer using six ring-shank nails. Total repair time: 6 minutes.
Pallet returned to Grade B service with full racking capability. Load capacity restored to 2,800 lbs dynamic / 4,600 lbs static. Total repair cost: $6.50 versus $16 for a new pallet.
Block Pallet with 3 Crushed Corner Blocks
A 48x40 block pallet used under heavy machinery had three corner blocks split vertically from compression overload. The pallet was unstable and could not be safely forked from two directions.
All three damaged blocks were removed and replaced with new 4x4x6 hardwood blocks. The top and bottom deck boards in the corner areas were inspected and re-nailed where fasteners had loosened during block failure. Total repair time: 12 minutes.
Pallet restored to Grade A block pallet specification with full four-way entry. Total repair cost: $9.50 versus $22 for a new block pallet.
Weathered Pallet Full Recondition
A stack of 200 pallets had been stored outdoors uncovered for 6+ months. The wood was gray, surface-weathered, and many boards had checked (small surface cracks from UV and moisture cycling). Several boards per pallet were loose from nail corrosion.
Each pallet was run through our repair line for re-nailing (average 8 nails per pallet), and boards with checks deeper than 1/4 inch were replaced. Average 1.3 boards replaced per pallet. Total average repair time: 4 minutes per pallet.
All 200 pallets returned to Grade B service. While the wood retains its weathered color, every board is structurally sound and all nails are tight. Average repair cost: $3.80 per pallet versus $14-16 each for new pallets. Client saved over $2,000 on this single batch.
Request Pallet Repair
Describe the damage type and quantity.