Repair & Refurbishment
Why replace when you can repair? Our expert team gives damaged pallets a new lease on life.
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Repair Services
Pallet repair is one of the most cost-effective and environmentally friendly services we offer. A damaged pallet that would otherwise go to the landfill can be restored to full functionality for a fraction of the cost of a new pallet.
Our repair team handles everything from simple board replacements to complete deck rebuilds. We use a combination of reclaimed and new lumber, ensuring each repaired pallet meets our quality standards. Operations Manager Oakley Thorne oversees our repair line to ensure consistent quality and throughput across every shift.
On average, repairing a pallet costs 50-75% less than purchasing a new one of equivalent grade. The environmental savings are even more dramatic — repair requires just 5-10% of the energy needed to manufacture a new pallet.
Whether you are a manufacturer with a fleet of worn pallets, a warehouse that has accumulated damaged units, or a distributor looking to extend the life of your pallet inventory, our repair service delivers tangible financial and environmental returns. We process over 500 repairs per day at our facility on 3240 Patton Way, Bakersfield, CA 93308, and can scale to meet orders of any size.
What We Repair
Replacement with matched lumber. Dimensional accuracy guaranteed. We match board width, thickness, and wood species to maintain pallet uniformity.
Stringer reinforcement or full replacement to restore load capacity. We use companion stringers, stringer patches, or complete stringer replacements depending on the severity.
All fasteners driven flush or replaced. Eliminates product and worker injury risk. We inspect every fastener point on the pallet during repair.
Lead boards, inner boards, and support blocks replaced as needed. We rebuild incomplete pallets to full specification.
Stained or contaminated boards replaced. Full pallet cleaning available. Essential for food-grade and pharmaceutical applications.
Pallets re-squared to meet tolerance specifications for automated systems. Critical for customers using conveyor systems, ASRS, or automated racking.
Cost savings vs. buying new
Less energy than manufacturing
Average repair turnaround
Detailed Repair Services
Our repair capabilities range from quick single-board fixes to complete pallet rebuilds. Here is a detailed look at each type of repair we perform, the techniques used, and when each is appropriate.
Board Replacement (Top Deck)
The most common repair we perform. When one or more top deck boards are cracked, split, broken, or missing, we remove the damaged board and replace it with a board of matching dimensions and wood species. We use both reclaimed boards from our salvage inventory and new-cut lumber, depending on availability and customer requirements.
Damaged boards are removed using pry bars or a pneumatic board puller. Replacement boards are cut to size, positioned, and secured using ring-shank nails or helical nails driven by pneumatic nailers. We verify board spacing and flush fastener seating before the pallet moves to inspection.
Minutes per board. A single-board replacement takes approximately 2-3 minutes. Multi-board replacements are proportionally longer.
Board Replacement (Bottom Deck)
Bottom deck boards take significant abuse from forklift entry, conveyor systems, and floor contact. Cracked or missing bottom boards compromise the structural integrity of the pallet and can cause failures during transport or racking. We replace bottom boards with the same dimensional accuracy as top deck repairs.
The pallet is inverted for bottom deck access. Damaged boards are removed and replacements are cut, positioned, and nailed. For pallets used in automated systems, we pay particular attention to the bottom lead board, which is critical for conveyor and ASRS compatibility.
Similar to top deck replacement. Slightly longer due to the need to invert the pallet and work in a less accessible position.
Stringer Repair (Companion Stringer)
When a stringer is cracked but not completely broken, a companion stringer can be attached alongside the damaged one to restore load-bearing capacity. This is a cost-effective alternative to full stringer replacement and is appropriate when the crack does not extend through the entire stringer cross-section.
A companion stringer of matching dimensions is cut to length and secured to the side of the damaged stringer using nails or bolts. The companion shares the load with the original stringer, effectively doubling the strength at the repair point. This technique adds minimal weight and does not change the pallet dimensions.
Approximately 5-8 minutes per stringer repair. Bolted companions take slightly longer than nailed versions.
Stringer Replacement (Full)
When a stringer is broken through, severely rotted, or damaged beyond companion repair, the entire stringer must be replaced. This is a more involved repair that requires removing all boards from the damaged stringer, extracting the old stringer, inserting a new one, and reattaching all boards.
All deck boards connected to the damaged stringer are carefully detached. The broken stringer is removed. A new stringer (matched in species, dimensions, and notch pattern) is positioned and the deck boards are reattached. All fasteners are driven flush and the pallet is checked for square.
Approximately 15-20 minutes per full stringer replacement. This is one of our more time-intensive repairs.
Notch Repair
Forklift tine entry notches can become damaged or enlarged over time, especially in block pallets and four-way entry pallets. Damaged notches can cause forklift tines to slip or the pallet to sit unevenly on racking. We repair notches to restore proper forklift access and racking compatibility.
Depending on the damage, we either reinforce the existing notch with additional wood or cut a new notch to specification. For block pallets, damaged blocks are replaced with new blocks of matching dimensions. All notch repairs are verified for forklift tine clearance.
Approximately 5-10 minutes per notch, depending on the type and severity of damage.
Full Deck Rebuild
When the majority of deck boards are damaged but the stringers are sound, we perform a full deck rebuild. This involves removing all top deck boards (and sometimes bottom deck boards) and replacing them with new or reclaimed lumber. The result is effectively a new deck on existing stringers.
All deck boards are removed. Stringers are inspected and any stringer issues are addressed. New or reclaimed boards are cut to size and nailed in the correct pattern with proper spacing. The completed pallet is inspected for dimensional accuracy and structural integrity.
Approximately 20-30 minutes per pallet for a full top deck rebuild. Double-deck rebuilds take proportionally longer.
Re-Squaring & Dimensional Correction
Pallets used in automated warehouse systems (ASRS, conveyor lines, robotic palletizers) must meet tight dimensional tolerances. Over time, pallets can shift out of square due to stress, impacts, or component movement. We re-square pallets to meet your automated system specifications.
The pallet is placed on a flat surface and measured at all critical points. Out-of-spec components are repositioned, re-fastened, or replaced. The pallet is re-measured after correction. We can tighten tolerances to within 1/4 inch on all dimensions for automated system compatibility.
Approximately 10-15 minutes per pallet, depending on the degree of correction needed.
Fastener Maintenance
Protruding nails are one of the most common pallet defects. They damage products, injure workers, and snag on conveyor systems. Our fastener maintenance service addresses protruding, loose, or missing fasteners across the entire pallet.
Every fastener point on the pallet is inspected. Protruding nails are driven flush using pneumatic impact tools. Loose nails are pulled and replaced. Missing fasteners are added. We use ring-shank nails that resist pull-out better than smooth-shank nails, reducing the chance of recurrence.
Approximately 3-5 minutes per pallet for a full fastener inspection and correction.
Tools & Equipment
Our repair shop is equipped with professional-grade tools designed specifically for pallet repair and refurbishment. This equipment allows our technicians to work quickly and consistently, producing reliable results on every pallet.
High-speed nailers that drive ring-shank and helical nails for superior holding power. These are the workhorse tools of our repair line.
Powered pry tools that remove damaged boards quickly without damaging adjacent boards or stringers.
Machines that separate pallets into individual boards and stringers for salvage. Processes damaged pallets that are beyond repair.
Precision cutting saws used to cut replacement boards, stringers, and blocks to exact dimensions.
Used for ripping lumber to specific widths and thicknesses when standard sizes are not available.
Used for driving and extracting screws in pallets that use screw fastening systems rather than nails.
Tape measures, speed squares, and straightedges used to verify dimensional accuracy throughout the repair process.
Used to locate and verify removal of all metal fasteners during dismantling operations.
Quality Standards
Every repaired pallet that leaves our facility must meet the same quality standards as a non-repaired pallet of the same grade. We follow NWPCA (National Wooden Pallet and Container Association) guidelines and apply additional internal criteria to ensure consistency.
Structural Load Testing
Repaired pallets are tested to verify they support their rated load capacity without deflection beyond tolerance limits. We test both static and dynamic load scenarios.
Dimensional Accuracy
All repaired pallets are measured for length, width, and height. Standard tolerance is +/- 1/2 inch. For automated system customers, we tighten to +/- 1/4 inch.
Fastener Integrity
Every fastener on a repaired pallet is inspected for flush seating, proper depth, and holding power. No protruding nails, no loose fasteners, no exceptions.
Board Quality
Replacement boards must be free of severe knots, splits, rot, and insect damage. We grade every replacement board before installation.
Surface Condition
For food-grade and pharmaceutical customers, we perform enhanced surface inspections to check for staining, contamination, and mold. These pallets receive additional cleaning before delivery.
Grade Accuracy
After repair, the pallet is re-graded. If a customer orders Grade B repair, the finished pallet must visually and structurally meet Grade B criteria. Pallets that fall short are either re-worked or downgraded.
Repair Scenarios: Before & After
To illustrate the value of our repair service, here are several common scenarios we encounter and the outcomes we deliver. Each scenario represents a real type of damage we see regularly.
Warehouse Pallet Fleet Overhaul
A local distribution center had 800 pallets showing mixed damage: broken deck boards, protruding nails, cracked stringers, and out-of-square dimensions. Approximately 60% were classified as Grade C or below.
After repair, 720 pallets (90%) were restored to Grade B or better. The remaining 80 were dismantled for parts. The customer saved over 60% compared to replacing the entire fleet with new pallets.
Food Manufacturer Compliance Upgrade
A food processing company needed 500 pallets brought up to food-grade standards. Their existing inventory had staining, rough surfaces, and fastener issues that failed their quality audit.
We replaced all stained boards, drove all fasteners flush, smoothed rough surfaces, and provided a food-grade cleaning treatment. All 500 pallets passed the subsequent quality audit.
Automated Warehouse Dimensional Correction
An e-commerce fulfillment center reported frequent jams in their automated conveyor and racking system. Investigation revealed that 300 pallets were out of square by 1/2 to 1 inch — enough to cause machine failures.
We re-squared all 300 pallets to within 1/4 inch tolerance. Conveyor jams dropped to near zero. The customer avoided the cost of replacing functional pallets simply because of dimensional drift.
Agricultural Seasonal Pallet Refresh
A produce packer needed 1,200 pallets ready for harvest season. Their existing inventory had been stored outdoors and showed weathering, board warping, and fastener corrosion.
We replaced warped and weathered boards, treated fastener corrosion, and re-graded the entire fleet. Over 1,000 pallets were restored to Grade B, ready for the packing line. The remaining 200 were rebuilt with new deck boards on existing stringers.
The Economics of Pallet Repair
Pallet repair delivers compelling financial returns for businesses of all sizes. Here is a breakdown of why repair is almost always more economical than replacement, and how the savings compound over the life of a pallet fleet.
Per-Pallet Cost Comparison
Full manufacturing cost including lumber, labor, fasteners, and margin
A used pallet in excellent condition — our most cost-effective standard option
Simple board replacement on a structurally sound pallet
More extensive repair including stringer work
Nearly complete rebuild using existing stringers and new deck boards
Fleet Lifecycle Savings
A pallet is not a single-use item. A well-maintained pallet can go through 10 or more use cycles before it reaches end of life. Each repair extends the pallet by several more cycles, compounding your savings over time.
Consider a fleet of 1,000 pallets. Over a 3-year period, a repair-first strategy (repairing pallets as they wear rather than discarding and replacing them) typically reduces total pallet spending by 40-60% compared to a replace-only approach. The exact savings depend on usage intensity, but the principle holds across virtually all industries.
Environmental savings are an additional benefit. Each repaired pallet conserves approximately 3.5 board feet of lumber, prevents 25-30 pounds of CO2 emissions associated with new manufacturing, and keeps approximately 50 pounds of wood out of the landfill. For a fleet of 1,000 pallets repaired annually, that adds up to meaningful environmental impact.
Annual Savings Example (1,000-pallet fleet)
Repair Turnaround Times
We understand that downtime costs money. Our repair operation is designed for speed without sacrificing quality. Here is what to expect for various order sizes and repair types.
Small Orders (1-50 pallets)
Most small orders completed same day if received in the morning. Guaranteed next-business-day.
Medium Orders (50-200 pallets)
Processed within 1-2 business days. Priority scheduling available for time-sensitive orders.
Large Orders (200-500 pallets)
Batched into our repair queue. Timeline depends on repair complexity and current capacity.
Fleet Orders (500+ pallets)
Enterprise-scale repairs scheduled with a dedicated timeline. We can process in batches for partial delivery.
Rush Service
Available for small to medium orders at a premium rate. Contact us to confirm availability for your specific needs.
Recurring Repair Programs
For customers with continuous repair needs, we set up standing repair queues with guaranteed weekly or bi-weekly turnaround.
How to Submit Pallets for Repair
Drop-Off
Bring your pallets to our facility at 3240 Patton Way, Bakersfield, CA 93308, during business hours. We assess, quote, and begin repairs immediately.
Pickup
We send our truck to collect your damaged pallets. Pickup is scheduled at your convenience, and we return the repaired pallets on a separate delivery.
On-Site Repair
For very large orders, we can dispatch a repair crew to your location. This is ideal for warehouse-wide fleet overhauls where transporting pallets both ways is impractical.
Extend the Life of Your Pallets
Stop discarding damaged pallets. Our repair services save you money, reduce waste, and keep your operation running smoothly. Use the form at the top of this page or visit us at 3240 Patton Way, Bakersfield, CA 93308.
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