Introduction: How to Disassemble a Pallet

As an avid pallet recycler w >100 pallets disassembled & repurposed this summer, I am sympathetic to the pains & frustrations of disassembly. But when I heard that someone took 6 hard hours to take a single pallet apart when I do it daily w 100% usability in <7 minutes, I knew I needed to tell folks that there was a better way.

Step 1: Pallet Construction

Pallets are built strong to hold tremendous weight on top, yet light to facilitate transport of that weight. Because of the multitude of loads, there's no specific "standard" pallet, just more or less common in a given industry. Since most of my projects are 4' in size (benches, tables, etc.), I tend to accumulate more pallets w 48" slats than other sizes, but I've got small 36" wide pallets & 60" long pallets & everything in between.

Basic construction regardless of size is a 2x4 (w or w/o fork cutouts) to support the top (more slats) & held vertical by the bottom slats (fewer). Pallets that hold heavier weight (such as bottled water) usually have 4x4 blocks instead of 2x4s boards.

The slats are usually 1x4 or 1x6 secured via pneumatic nail gun w spiral twisted nails pretreated w glue. The heat from forced entry activates the glue. The twist prevents pull out. Since pallets can have a LONG lifespan & extensive reuse, they are designed to NOT come apart.

They are also treated to prevent rot. Some make a huge "life threatening" speech about Methyl & Ethel chemical treatment, but I haven't found one of these pallets yet. Maybe it's a regulation thing of what they used to do back in the '80s or something. Of the 109 pallets that I've brought home & the 1,000+ I've seen in piles around town, ALL of them are stamped w the HT code for "Heat Treated". Stay safe, but don't let the scaredy cats freak u out too bad.

Step 2: Disassembly Options

Most DIY folks use hammer, pry bar, & homemade wood or metal contraptions to pry the slats off the 2x4s. This has 3 BIG problems:

  1. Work
    I'm lazy. I don't like to break a sweat over a simple task when I've got better things to spend my energy on.
  2. Time
    Breaking pallets down by brute force takes forever! Each nail has to be pulled & prodded. Each slat has to be tapped & twisted. Then u have to denail each board or risk scrapes & worse.
  3. C) Damage
    Even worse than all that, you spend 30 minutes to an hour ripping the pallets apart only to end up w splinters & short pieces that won't build what u wanted the pallet to begin w. 3 pallets w 15 slats each might only yield 35 usable boards. Unless u need a reliable source of kindling, there has to be a better way.

    A quick search online reveals industrial level pallet recycling machines that cost thousands but will allow 2 men to disassemble a pallet w no breakage in as little as 30 seconds. Another style of machine lets a single user disassemble a pallet in 45 seconds. Obviously, this isn't practical for the handyman trying to build on the cheap, but what do they do different? Instead of pulling the slats off w force, they CUT the nails!

Step 3: Reciprocating Saw

To give credit where it's due, I got this from Old World Farms.
For <$50 u can buy a brand new reciprocating saw. At pawn shops, garage sales or Craigslist, you can find them even cheaper. Sometimes called a Sawzall from the original machine built by Milwaukee Tools, these are awesome rough cut demolition tools. Insert the special blade between the slat & the 2x4 to cut the nail w no stress on the slat or you. Let the tool do the work!

Step 4: Saw Blades

Not all reciprocating saw blades are created equal. There are 4 basic styles:
A) Wood only
B) Metal only
C) Crosscut / Tree Trimmer
D) Bi-Metal
You want this last style. Not all of them are created equal either. Bostitch makes a great Nailcutter blade. Milwaukee makes a superb TheAxe blade. The secret is to not let the nail get too deep between the teeth to prevent tooth breakage.

Step 5: Process

Step 1) I prefer using a 6" Bostitch Nailcutter on the ends. These were on sale @ WalMart so I bought several packages. 6" doesn't bend much, & these blades last a good dozen or more pallets each. 2/3 done!

Step 2) Switch to 9" Milwaukee TheAxe blade. Keep your blade straight & work the middle support.

Step 3) Denailing is optional, but if u really want or need to, the slats are easy w just a dull nail to drive them up & a quick pull out. 2x4s are a bit trickier but can be done w a slice down the middle long ways w a circ saw followed by the dull nail & wire cutters.

Video

Comments

author
KellyW90 (author)2016-06-20

Thanks! Should my sawzell be set to orbital mode? I have a demolition blade and still am having some difficulty breaking down the boards. Thanks!

author
BryanM81 (author)2016-06-16

THANK YOU! I was looking for a way to break down some pallets for a gate, and dreaded the thought of so much time with a hammer and crowbar. Bought a sawzall and saved SO MUCH TIME and wood. Also, I have other uses for this amazing tool.

author
jazzza (author)2016-04-18

Thank you, so simple

author
avgiancola (author)2016-02-18

followed the video - Great movie! Thank you!

author
avgiancola (author)2016-02-18

followed the video - Great movie! Thank you!

author
avgiancola (author)2016-02-18

followed the video - Great movie! Thank you!

author
Robert HH (author)2014-11-28

HI, good advice. I'm a retired heavy construction guy (30 + years, millwright, ironworker, pipefitter, sheetmetal mechanic, and wrote the textbooks used in a lot of community colleges on those subjects, the Pearson Contren series) This is exactly where the Sawzall comes into its own. It is used in remodeling and demolition work the same way. Good to see you present it to recyclers....

author
MicheleD36 (author)Robert HH2016-01-10

Robert,

I am also a Pearson writer and own a small B&B. Any chance you'd like to consider a shed remodel using all your skills and a great imagination??? Cool gig for a retired guy. We're on Smith Island, MD at smithislandinn.com Serious offer, let me know if any interest. innkeeper@smithislandinn.com

author
135steward (author)2015-12-03

This works great! I got a cheap Porter-Cable Sawzall, some 6" and 9" blades rated for wood with nails, and broke down my first pallet in about 20 minutes! I'm sure I'll get faster with practice. The 40 board feet of 1x4's and 12 board feet of 2x2's (I trimmed the main boards) was well worth the effort. Thanks!

author
135steward (author)2015-09-24

I may try using a jigsaw. I have one of those.

author
crtorrespr (author)2015-04-20

Works excellent!

author
jacob_st (author)2015-04-11

Good info thank you. For longer timber slats, I have used a std. car jack to wedge the timber apart. It's fiddly and you have to move the jack up and down each slat until the timber is wedge apart. Some nail heads will pull through the timber due to nail glue etc. Give it a go!

author
jehowe8 (author)2015-03-27

Love this! Thanks!

author
bo88y (author)2015-01-08

To denail, I would use a 1/16" or 3/32" nailset with a rubber jacket. Stanley makes a set of three sizes for about $10. Unless you have tiny little hands, they're easier to hold than the shorter, unjacketed ones (5" vs. 4"), and provide a little cushioning for whatever side thrust occurs from a not-perfectly-straight hammer strike. If you're using one all day, both of these factors make a noticeable difference.

author
nhampto9 (author)bo88y2015-01-08

This suggestion is excessive & unnecessary. Most nails only take one or two taps before they're exposed enough to pull. We're not talking a lot of serious nailing. If u have it, use it, but I wouldn't spend $10 extra just for this use.

author
Chuck Priest made it! (author)2014-12-11

Great Instructable, it really sped up my deconstruction time using the Saw Zaw and less wood was damaged. Here is a picture of all the Holiday Wine rack gifts I was able to make out of 2 pallets; I still have wood enough for one or two more.

photo(4).JPG
author
nhampto9 (author)2014-12-08

@ abeaule
I've made 1 desk, but I need 2 or 3 more. I'll probably do an Instructable on it.

author
asbeaule (author)2014-11-28

I'm currently building a desk from pallet wood. I really wish I'd seen this before dismantling them and had those tools.. It was such a pain to do ! Pallet wood is brilliant to make stuff though. Nice sturdy wood.

author
vanweb (author)2014-11-25

We needed our wood to be mostly nail free but we could afford to loose a bit of length so what we did (on 130 pallets in 3 days) was to cut the end rails off with a circular saw just inside of where it was nailed. That left just the center bar holding the slats. with this you could easily wiggle the slats a bit loose the just use a pry bar down the middle. As you said many pallets actually use spiral nails with epoxy so they are very difficult to get out so any way to avoid pulling them one by one is a good way!

https://www.instructables.com/id/How-to-use-Free-Pallets-to-Build-a-BBQ-Restaurant/

author
pfred2 (author)vanweb2014-11-27

When I took apart pallets I did it how you did it. I'd use a circular saw just on the insides of the nails. Losing an inch of slat was no big deal, and messing with those nails increased the chance of a slat splitting anyways.

author
acheide (author)2014-11-26

Nice way to process waste pallets for re-use.

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