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Absolutely! And it’s not as complicated as you might think. In fact, if you choose second-hand plastic pallets, the price can even be cheaper than ordering a wooden deck, and they’re far more durable.
As a plastic pallet manufacturer, we’re here to provide you with reliable advice on building your platform using pallets. So, let’s relax, get creative, and unleash your DIY potential!
Where Can You Get Plastic Pallets?
Some people online say you can just call Pepsi and ask for free pallets, but to be honest, they might not be so quick to hand them over. As one of Pepsi’s plastic pallet suppliers, we know that the number of pallets they use at their factories is carefully matched to what they actually need. And even if they do need to replace some, they’re all about sustainability, so those pallets usually go straight into their closed-loop recycling system first.
So, what’s the best option? Well, you might want to check out second-hand markets – you can often find pallets in good shape for a pretty decent price.
If you’re working on a DIY plastic pallet project, you can also consider reaching out to us for brand-new plastic pallets. The prices aren’t as high as you might think – our heavy-duty pallets can carry up to 4 toneladas, and for most backyard projects, a 1-ton capacity pallet is more than enough. And honestly, the price of a 1-ton pallet is pretty much on par with buying a used heavy-duty pallet elsewhere.
What Size Pallets Should You Order?
Now that you know where to get plastic pallets, let’s talk about how to calculate the pallet size you need.
In the U.S., you can often find 48” x 40” pallets in the second-hand market (roughly 1210mm x 1016mm x 150mm). Keep in mind that plastic pallets cannot be cut to size, so it’s best to choose the pallet size that best suits your space. If you’re planning to align them with the width of your home or garden, you might need to slightly adjust your expectations for a perfect fit.
Here are some additional scenarios to consider when choosing the right pallet size for your project:
| Scenario | Recommended Pallet Size | Number of Pallets | Suggested Dimensions | Additional Tips |
| Garden Deck or Platform | 1-ton capacity pallets (48″ x 40″) | 6 pallets (for a 10ft x 10ft area) | 1210mm x 1016mm x 150mm | Use measuring tape to measure your space before ordering. Leave extra space between pallets for airflow. |
| Poolside Deck | 1-ton or 2-ton capacity pallets | 9 to 12 pallets (for a 12ft x 12ft area) | 1210mm x 1016mm x 150mm | Choose larger pallets if you plan to place poolside furniture or heavy equipment. Ensure the platform can handle the weight. |
| BBQ or Outdoor Kitchen Area | 4-ton capacity pallets | 6 to 8 pallets (for an 8ft x 12ft area) | 1210mm x 1016mm x 150mm | Ensure pallets can support heavy BBQ grills or kitchen equipment. Consider the weight capacity and use larger pallets if necessary. |
| Event Platform or Stage | 2-ton capacity pallets or larger | 12 to 15 pallets (for an 18ft x 18ft area) | 1210mm x 1016mm x 150mm | Consider higher load capacities for crowd support. Use extra pallets for weight distribution. |
| Storage Platform in Garage | 1-ton or 2-ton capacity pallets | 7 to 8 pallets (for a 10ft x 12ft area) | 1210mm x 1016mm x 150mm | Leave space between pallets to improve ventilation and easy access to stored items. |
By following these tips, you can be sure you’re selecting the right pallet size for your DIY project. Whether it’s for a small porch or a large outdoor platform, proper sizing is key to ensuring both stability and aesthetic appeal.
Materials and Equipment You Needed
Once you have your plastic pallets, you’ll need to gather the following items. Without these materials, your pallet deck may have some potential issues.
- Palets de Plastico(determine the specifications and the quantity you need)
- Bottom layer materials (gravel or stones for increasing friction and stability on the ground)
- Concrete bricks (4 concrete bricks per pallet for support)
- Wood glue or construction adhesive
- Decking boards (wooden planks)
- Measuring tape(helps you measure distances accurately)
- Saw (for cutting decking boards if needed)
- Rake (for leveling ground materials)
- Deck screws or long wood screws
- Hammer or electric drill
- Galvanized steel pipes (for added stability between pallets – we as pallet manufacturers also use these for reinforcement to ensure maximum stability)
How to Build a DIY Plastic Deck Out of Pallets
Once you’ve measured the space, determined the pallet size, and ordered the required number of pallets, you can begin building your deck. We’ve put together 6 simple steps to guide you through the process.
Step 1: Prepare the Ground
Start by leveling the ground where you plan to build your deck. Use a rake to spread the gravel or small stones evenly across the area. Make sure the gravel area is slightly larger than the size of the pallets you will be using. This will create a stable foundation, and even if there’s some extra gravel around the pallets, it will be easy to clean up later.
Step 2: Set Up the Pallets
To start, place four concrete bricks under each corner of the area where you’ll set the pallets. These bricks will lift the pallets off the ground, helping to prevent moisture damage and keeping the structure more stable.
Next, apply wood glue or construction adhesive on top of each brick. After that, carefully place the plastic pallets on top of the bricks. This will help keep the pallets in place and prevent them from moving around.
Note: Make sure the pallets and bricks stay parallel to each other. Try to avoid any tilting to ensure the structure remains stable.
Step 3: Stabilize the Pallets Using Wooden Slats or Steel Pipes
No matter what type of pallet you’re using, we recommend first connecting the pallets as a whole for added strength.
1. Wooden Slats: If your pallets have runners at the bottom, you can place wooden slats either (but only in one direction). Use nails to secure the slats in place. This will help hold the pallets together and prevent them from shifting.
2. Galvanized Steel Pipes: If your pallets have square holes diameter between 25mm and 30mm (specifically designed for steel pipes), you can use galvanized steel pipes to connect the pallets. This option is different from the wooden slats, and you’ll need to ensure your pallets have the pre-drilled holes to accommodate the pipes before purchasing them. This connection method is far more stable than using wooden slats.pallets together and prevent them from shifting.
3. Alternative Method – Using Long Bolts and Nuts (with Washers): If you prefer using long bolts and nuts (with washers) to connect the pallets, we suggest first drilling holes on the sides of the pallets. You can choose self-tapping screws with fine threads and sharp points (the length depends on the thickness of the wood and pallet plastic). Use a low-speed setting on your electric screwdriver to drill two parallel holes along the edge or thick wall of each pallet. Then, drill through the legs of two adjacent pallets and tighten them securely.
After the screws are in place, we also recommend using heavy-duty nylon zip ties. Thread them through the wood and the pallet’s grid bars, pulling them tight in a cross pattern and tying them off. Make sure the spacing between the zip ties is about 15cm.
Step 4: Lay the Decking Boards
Once the pallets are secured and stable, it’s time to lay the wooden decking boards on top. Start from one side and work your way across, ensuring the boards are aligned correctly. For added stability, you may need to trim the decking boards to fit the dimensions of the pallets.
Step 5: Secure the Decking Boards with Screws
After positioning the wood decking boards, begin fixing them to the plastic pallets. Use deck screws or long wood screws to secure the boards to the pallets.
Important Tip: When securing the decking boards with screws, remember not to immediately drive the screws all the way in. First, ensure the boards are correctly aligned with the pallets and adjust them if necessary. Only after confirming their position should you use a hammer or screwdriver to fully tighten the screws. This step is crucial to prevent any misalignment and ensure a stable, long-lasting deck.
Step 6: Finishing Touches
Check all screws and make sure the boards are tightly fixed in place. If necessary, add more screws to any loose spots. Once the deck is secure, you can apply a weatherproof sealant or wood finish to enhance the durability of the wood.
By following these steps, you’ll have a sturdy and reliable plastic deck made from pallets, perfect for outdoor spaces or DIY projects!
How to Secure Plastic Pallets with Screws When There Are Gaps in the Grid
A lot of people ask how to secure plastic pallets with screws, especially since the grid structure often makes it hard to tighten the screws properly. If the methods we’ve covered so far aren’t working for you, here are three more solutions you can try:
1. Switch to Screws Designed for Gridded Structures
Butterfly Expansion Screws are perfect for grid structures. Simply place the wooden board on the pallet, drill through the gaps, and as you tighten the screw, the wings expand and lock into the pallet’s bottom grid. This method doesn’t rely on the plastic thickness and offers a super secure connection.
2. Add an Extra Layer of Reinforcement
To prevent screws from damaging the plastic, place a thin metal (like aluminum) or thicker plastic sheet between the wood and the pallet. This helps distribute the pressure, stopping screws from sinking into the grid or cracking the plastic.
3. Use Hot Glue or Plastic Adhesive for Extra Hold
If you’re worried about cracking, apply a bit of hot glue or plastic adhesive to the drilled holes before inserting the screws. This will strengthen the hold and protect the plastic from damage.
Important: Let the glue dry for about 5-10 minutes before fully tightening the screws. This will enhance the stability and durability of the connection.
Conclusion: Why Choose Plastic Pallets for Your DIY Platform?
Now that you know exactly how to build your plastic pallet platform, let’s quickly highlight the advantages of choosing plastic pallets:
- Longer lifespan: Plastic pallets are built to last much longer than wood pallets, providing great value over time.
- Environmentally friendly: Made from HDPE/PP, plastic pallets don’t contribute to deforestation like wood pallets do.
- Easy to clean: Simply hose them down with water for quick and easy maintenance – no need for complex cleaning procedures.
- Strong weight capacity: They can handle heavy loads, making them perfect for any platform where people will walk or place equipment.
No doubt about it, as a pallet manufacturer, Enlightening Pallet offers 600+ models and 100+ sizes, far more variety than what you’ll find in the second-hand market. Plus, with used pallets, you never really know how much life they’ve got left.
So why wait? Contact us today to discuss your DIY platform ideas, and let’s make it happen!
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