How to repair a cracked plastic pallet
A cracked plastic pallet is repaired by welding the crack or swapping the broken part, since plastic is hard to glue. Whether a repair is worth doing depends on where the crack is and what the pallet will carry afterwards.
- Methods
- Welding, part swap
- Glue
- Hard; HDPE is hard to glue
- HDPE melts at
- About 131.8 C
- Snap-lock designs
- Made for quick repair
Where the crack is decides
| Crack at | Repair | Afterwards |
|---|---|---|
| Deck rib, away from edges | Weld possible | Floor-level use, declared |
| Deck edge | Often a reject | Edges take the fork and the rack |
| Leg or foot | Weld or swap | Do not rack |
| Runner end | Often a reject | Runners carry the floor load |
| Snap-lock joint | Swap the part | As good as the maker's part |
| Hairline in a corner | Watch, do not repair | Retire if it grows |
Why plastic repair is harder than wood
With wood you nail a new board. With plastic you must join like to like. HDPE has resin code 2, a density of 930 to 970 kg/m3 and melts at about 131.8 C, and it is hard to glue, so joints are usually welded. A weld is a local melt, and a bad one can leave the part weaker than it was. Some designs avoid the problem with parts that snap in and out.
What it means for a buyer
Most buyers do not repair pallets; they buy pallets that someone repaired. The question is what was done and whether it was done well. Ask for a count of welds and swaps and where they are. A repaired pallet is not a bad pallet, but it is a different grade, and it does not belong on a rack.
- Ask where each weld is
- Ask whether swapped parts are the maker's own
- Do not use a repaired pallet for racking
Repair is a process with limits
Plastic can be welded, riveted or fitted with a replacement part, and each repair has limits. A crack near a load point is a worse place for a repair than a crack in a decorative rib. Check the maker's guidance before repairing, and test a repaired pallet with a safe load before it goes into service. If a repair changes the design the rating assumed, the rating should not be relied on.
Record what was done and where. A note on the pallet or in a lot description tells the next buyer what to expect.
Tools and conditions for a repair
A repair needs clean surfaces, the right resin, enough heat to fuse without scorching, and time to cool in shape. Work in a ventilated place, wear gloves and eye protection, and let the joint cool before it is loaded. A repair done in a hurry on a dirty crack usually fails at the same point. If you do not have the tools or the training, send the pallet to a repairer rather than improvising.
What to write down about a lot
- Footprint in both units, with the readings you took rather than the label.
- Number of stacks, pallets per stack and any odd stacks left over.
- Makers and model numbers seen on plates or moulded into the ribs.
- Count of repaired, mismatched or cracked pieces, and where each sits.
- Marks, colours and any smell, with a note on who confirmed each.
When something looks wrong
- Stop unloading and photograph the fault before anything moves.
- Count how many pallets show the same fault, to see if it is a lot problem or a one-off.
- Tell the desk or the seller in writing the same day, with the photographs attached.
- Hold the affected stacks apart until you hear back.
- Keep one sample pallet unused, so the maker or an inspector can examine it.
Walk-around checklist
The same four stops for every lot, in order. Tick each as you go.
- 1Deck: weld seams inspected for fusion
- 2Corners: weld at corners checked for cracks beside it
- 3Runners: runner weld judged for flatness
- 4Fork pockets: pocket weld judged for distortion
- Count of repairs written
Words used on this page
- Runners
- Bottom rails that touch the floor or rack and carry the load.
- HDPE
- High-density polyethylene, resin code 2. The most common resin in plastic pallets; tough and moisture resistant.
- Racking load
- Weight a pallet carries bridging an open span in unsupported racking. Often the lowest rating.
- Fork pocket
- Opening in the pallet where the forks go.
- Resin identification code
- Number on a plastic part for the resin, which does not itself say whether it is recyclable.
What the sources say
- HDPE has resin identification code 2, a density of 930 to 970 kg/m3, melts at 131.8 C and is hard to glue, so joints are usually welded. en.wikipedia.org
- Rehrig Pacific's rackable pallet has a two-piece snap-lock design for quick repair and options for FDA-approved colours, RFID and up to 15 percent black recycled content. rehrigpacific.com
- HDPE is the most common resin in plastic pallets; PP is more rigid and the page recommends it for unsupported racking. nelsoncompany.com
- 48 x 48 plastic pallets hold four 55-gallon drums without overhang; 48 x 45 matches North American auto parts bulk containers. nelsoncompany.com
How a request works
- Pick the footprint, then the grade you can live with.
- Say what the pallets will carry and how many you need.
- Read the written lot description that comes back.
- Agree the lot before anything moves.
The four grades, in a line each
- Like new. A few trips only. Clean, no cracks, no missing parts, deck and runners flat.
- Used and clean. Many trips, scuffs and colour variation, but whole and usable for general-purpose or closed-loop work.
- Repaired. A cracked or chipped part welded or swapped. Some designs use snap-lock parts for repair.
- Mixed lot. Mixed makers, colours and sizes sold by the truckload, sorted by footprint.
Questions people ask
How do you repair a cracked plastic pallet?
Weld the crack or swap the broken part. Plastic is hard to glue.
Can I glue a plastic pallet?
HDPE is hard to glue, so joints are usually welded.
Is a repaired pallet safe?
For floor use, often. For racking, not without the maker's say.
Ask for a lot
Pick a footprint and a grade. The reply describes a matched lot in writing.