Pallet Repair
Professional repair and refurbishment that extends pallet life and saves you 50% or more compared to buying new.
Request Pallet Repair Service
Tell us about the pallets you need repaired: quantity, type of damage, and size. We will provide a repair estimate.
Pallet Repair Capabilities
A damaged pallet is not a disposable pallet. In most cases, repairing a pallet costs 30 to 60 percent less than buying a new one and produces a result that is functionally identical. At SD Re Pallet, pallet repair is one of our core competencies. Our repair team processes hundreds of pallets daily, restoring them to service-ready condition with fast turnaround and consistent quality.
We repair pallets of all sizes and types, from standard GMA 48x40 to custom and non-standard dimensions. We work with both stringer pallets and block pallets, and we repair both hardwood and softwood constructions. Whether your pallets have a single cracked board or need extensive refurbishment, we have the capability and the inventory of repair lumber to get it done.
Types of Repairs We Perform
Board Replacement
The most common repair. Cracked, split, or missing deck boards are removed and replaced with quality lumber matched to the original board dimensions. We replace top deck boards, bottom boards, and lead boards (the boards at the pallet entry points that take the most forklift abuse).
Typical repair: 1-4 boards per pallet. Fast turnaround, lowest per-pallet repair cost.
Redecking
When most or all of the deck boards are damaged but the stringers and structure are sound, redecking is the answer. We strip the damaged deck and install a complete set of new boards on the existing frame. Redecking produces a pallet with a like-new deck surface at a fraction of the cost of a fully new pallet.
Ideal when stringers are solid but deck boards have taken heavy wear.
Stringer Repair
Damaged stringers compromise pallet structural integrity and load-bearing capacity. We repair cracked or broken stringers using companion boards, which are cut-to-fit reinforcing pieces nailed alongside the damaged stringer to restore full strength. For severely damaged stringers, we perform full stringer replacement.
Critical for safety. A pallet with a broken stringer should not be used until repaired.
Restacking
Pallets that have become warped, twisted, or dimensionally inconsistent can sometimes be restacked. We disassemble the pallet, square up or replace the frame components, and reassemble with proper alignment and nailing. This is especially common for pallets that have been stored outdoors and exposed to weather.
Restores dimensional accuracy for racking and automated systems.
Re-nailing and Fastener Repair
Over time, nails work loose from repeated impact, loading, and vibration. Loose nails create safety hazards and reduce pallet integrity. Our repair process includes pulling and replacing loose or protruding nails, adding additional fasteners where needed, and ensuring every connection is tight and properly seated. We use ring-shank or screw-shank pallet nails that resist pull-out significantly better than smooth-shank nails.
Cost Savings vs. Buying New
50-70% Savings
A standard board replacement repair typically costs 50 to 70 percent less than purchasing a new pallet of equivalent size and grade. For a business using 1,000 pallets per month, the annual savings from repairing instead of replacing can reach tens of thousands of dollars.
Extended Lifespan
A wood pallet that is properly maintained and repaired can go through 15 to 20 use cycles before it reaches true end of life. Without repair, most pallets are discarded after 5 to 7 trips. Repair effectively triples the useful life of your pallet investment.
Environmental Benefit
Every repaired pallet is one less pallet manufactured from new lumber. Repair reduces demand for virgin wood, lowers the energy and carbon footprint of your pallet supply, and keeps usable wood in service instead of sending it to a landfill. Learn more about our sustainability mission.
Quality Standards
Every repaired pallet leaves our facility meeting the same structural and dimensional standards as our recycled and new pallet inventory. We do not cut corners on repair quality because a failed pallet in your supply chain damages your products, your reputation, and our reputation.
Our quality standards for repaired pallets include:
- Replacement boards matched to original dimensions within 1/8 inch
- All fasteners properly seated and flush with board surface
- Stringer repairs tested for load-bearing integrity
- Dimensional accuracy verified: square, flat, and within tolerance
- Final visual inspection for missed damage, protruding nails, or loose components
- Grade assignment reflecting post-repair condition
Our repair quality is documented through our process standards and verified through industry certifications.
How Our Repair Service Works
Assessment
Contact us with the quantity and general condition of pallets needing repair. Send photos if available. We provide a repair estimate.
Pickup or Drop-Off
Bring pallets to our facility or we pick them up. For ongoing repair programs, we schedule regular pickups of damaged pallets from your site.
Repair
Our team inspects each pallet, determines the required repairs, and performs the work. Standard turnaround is 3-5 business days depending on volume.
Return Delivery
Repaired pallets are delivered back to your facility, ready for immediate use. See our delivery options.
Repair Types and Cost Ranges
Repair pricing depends on the type and extent of damage. Here is a breakdown of our most common repairs with typical cost ranges for standard 48x40 GMA pallets.
| Repair Type | Typical Cost | vs. New Pallet Cost | Turnaround | Savings |
|---|---|---|---|---|
| Single board replacement | $1.50 - $3.00 | $9-$14 (new) | 1-2 days | 75-85% |
| Multi-board replacement (2-4) | $2.50 - $5.00 | $9-$14 (new) | 2-3 days | 55-72% |
| Full redecking | $4.50 - $7.00 | $9-$14 (new) | 3-5 days | 40-55% |
| Stringer repair (companion board) | $2.00 - $4.00 | $9-$14 (new) | 2-3 days | 60-78% |
| Full stringer replacement | $4.00 - $6.50 | $9-$14 (new) | 3-5 days | 45-55% |
| Complete restacking | $5.00 - $8.00 | $9-$14 (new) | 5-7 days | 30-45% |
Pricing is per pallet. Volume discounts apply for repair batches of 100+ pallets. Custom and non-standard size pallets may vary. Contact us for a specific repair estimate on your pallets.
Before and After: Quality Specifications
| Specification | Before Repair (Typical) | After Repair (Guaranteed) |
|---|---|---|
| Load capacity | Compromised (unsafe for standard loads) | Restored to 2,500 lb dynamic / 2,800 lb static |
| Dimensional accuracy | May be warped, twisted, or out of square | Within +/- 1/4 inch of nominal dimensions |
| Deck surface | Broken, missing, or split boards | All boards intact, no gaps exceeding 1/2 inch |
| Stringer integrity | Cracked, broken, or split stringers | Full structural strength restored |
| Fasteners | Loose, protruding, or missing nails | All nails flush-set, ring-shank for pull-out resistance |
| Rackability | Not suitable for racking systems | Meets rack system requirements (Grade A/B repairs) |
On-Site vs. Off-Site Repair
Off-Site Repair (at Our Facility)
- Best for: Batches of 25-500 pallets
- We pick up damaged pallets and return repaired ones
- Full quality control in our controlled environment
- Access to complete lumber inventory for board matching
- Standard turnaround: 3-5 business days
- Lower per-unit cost due to production line efficiency
Recommended for most businesses.
On-Site Repair (at Your Facility)
- Best for: High-volume operations (500+ pallets/month)
- Our crew works at your location on a scheduled basis
- Eliminates transportation time and double-handling
- Pallets repaired and returned to service same day
- Ideal for distribution centers with continuous pallet flow
- Available as part of managed programs
Requires adequate workspace and is part of our management programs.
Warranty on Repairs
Every repair we perform carries a 90-day structural warranty. If any repair we made fails under normal use conditions within 90 days of return delivery, we re-repair or replace the pallet at no charge.
Our warranty covers the specific repair performed: replacement boards, stringer reinforcements, and fastener work. It does not cover new damage from forklift impact, overloading beyond rated capacity, or exposure to conditions outside normal warehouse environments.
For managed program clients, warranty coverage extends to 180 days and includes expedited replacement processing. Warranty claims are handled within 2 business days with no paperwork burden on the customer.
Common Damage Types and Fixes
Forklift tine puncture (deck board)
Fix: Board replacement with matched lumber
Very common (40% of repairs)
Split lead board from impact
Fix: Lead board replacement with reinforced nailing
Common (25% of repairs)
Cracked center stringer
Fix: Companion board reinforcement
Common (15% of repairs)
Missing bottom boards
Fix: Board replacement, re-nailing
Moderate (10% of repairs)
Warped or twisted frame
Fix: Restacking with squared reassembly
Less common (5% of repairs)
Loose nails / nail pop-outs
Fix: Re-nailing with ring-shank fasteners
Ongoing (5% of repairs)
Stop Throwing Away Repairable Pallets
Most damaged pallets can be restored to full service at a fraction of the cost of replacement. Fill out the form above or contact us to start saving.