Reusing pallets for DIY outdoor projects is a fun, budget-friendly way to create unique pieces for your patio, garden, or yard. However, untreated pallet wood will deteriorate quickly when exposed to the elements. Properly treating pallet wood is crucial for outdoor use to prevent rotting, cracking, and premature failure. With a few simple steps, you can weatherproof and beautify reclaimed pallets for planters, furniture, raised beds, and more!
Choosing Pallets for Outdoor Projects
Not all pallets are created equal when it comes to durability. Here are some tips for selecting pallets to reuse as outdoor wood:
- Opt for heat-treated pallets – Avoid chemically-treated pallets as the chemicals can leach into soil and plants. Look for markings like HT (heat-treated) or KD (kiln-dried).
- Use thick, sturdy boards – Thinner slats will deteriorate faster. Look for hardwood pallets made with wood like oak or ash. Softwoods like pine are more prone to rot.
- Check for broken or split boards – Avoid pallets with major damage as these will have a shorter lifespan outdoors.
- Select pallets with intact stringers – Stringers are the outer boards. Broken stringers weaken the whole pallet.
- Disassemble safely – Use PPE and tools like a pry bar, hammer, and crowbar to dislodge nails. Pull out all nails.
Proper pallet selection sets your project up for success from the start. Taking some time upfront to find quality material will ensure your finished project lasts outdoors.
Cleaning and Prepping Pallet Wood
Before treating pallet wood for outdoor use, it’s important to properly clean and prepare the boards:
Removing Debris
- Inspect all boards and use a stiff brush or steel wool to remove dirt, grime, stains, and loose wood fibers.
- For accumulated gunk and oil, use a degreaser like acetone, mineral spirits, or turpentine applied with a rag. Wipe clean.
- For extremely weathered pallets, consider sanding with 60-80 grit sandpaper to remove surface fibers and get down to fresh wood.
Killing Mold, Mildew and Fungus
- Mix 1 part bleach to 3 parts water in a spray bottle. Liberally spray pallet wood on both sides.
- Allow the boards to dry for 1-2 days. The bleach solution will kill mold and prevent future growth.
- For tougher mildew, use an enzymatic cleaner like Bac-Azap applied as directed.
- You can also use Concrobium Mold Control or hydrogen peroxide.
- After treatment, rinse the boards with clean water. Allow 1-2 days to dry fully.
Sealing Exposed End Grain
- Use a paintbrush to apply a coat of wood sealant like urethane to the end grain along the edges of the boards.
- Sealing the end grain prevents moisture absorption and rotting. Allow to dry fully.
With prep work complete, the pallet wood is ready for weatherproofing treatment.
How to Weatherproof Pallet Wood for Outdoor Use
When left unprotected and exposed to rain, sun, snow, and humidity, pallet wood will quickly start to crack, warp, rot, and attract mildew. Properly treating pallet wood before use in outdoor projects is crucial for longevity. Here are some options:
Using Exterior Wood Stain
Exterior wood stains offer UV protection, water repellency, and mold resistance. Consider using:
- Semi-transparent stains – Allow the wood grain to show while adding color. Requires more frequent reapplication.
- Solid stains – Contain more pigment so fully obscure the grain. Last longer than semi-transparent.
- Oil-based stains – Offer superior protection compared to latex stains. Require mineral spirits for cleanup.
- Choose weatherproofing colors – Medium to dark browns, greens, reds, and grays withstand weathering. Avoid bold colors.
Application Tips:
- Thoroughly stir and test stain colors on scrap wood first.
- Use a paintbrush, roller, or sprayer for full coverage on all sides and edges.
- Apply an even coat according to manufacturer directions. Avoid drips and thick spots.
- Allow proper drying time before adding a second coat or assembling projects.
Reapply exterior stain yearly or as needed to refresh protection.
Using Exterior Wood Finish
Clear exterior wood finishes like polyurethane, varnish, and epoxy provide protection without altering the natural color of pallet wood:
- Spar urethane – Durable, water-resistant finish good for outdoor use. Prevents graying.
- Marine varnish – Formulated to withstand sun and water exposure. Must recoat regularly.
- Penetrating epoxy – Seals and protects wood porosity deeply. Costly but long-lasting.
Application Tips:
- Prepare wood by sanding smooth. Remove dust.
- Apply 2-3 thin, even coats with a brush or foam roller. Avoid drips.
- Lightly sand between coats with 220 grit sandpaper.
- Allow proper drying times between coats.
- Top coats protect base coats, so don’t skimp.
Reapply 1-2 coats per year to maintain protection.
Using Exterior Paint
For a bolder, more vibrant look, you can paint pallet wood with exterior latex or oil-based paint:
- Primer – Use exterior wood primer first for better paint adhesion. Allow drying.
- Latex paint – More affordable, easier cleanup with soap and water. Requires more frequent repainting.
- Oil-based paint – Durable protection ideal for high-traffic areas like furniture. Needs mineral spirits to clean.
- Add texture – Consider using textured paints for slip resistance.
Application tips:
- Lightly sand pallet wood first to remove fibers and smooth surfaces.
- Use painters tape for crisp edges. Apply primer.
- Apply 2-3 thin coats of paint in long strokes using a quality brush, roller or spray paint.
- Allow proper dry time between coats. Lightly sand if needed.
- Remove all dried drips with sandpaper for a pro look.
Reapply fresh coats of exterior paint yearly or as needed.
Using a Wood Preservative
For severely weathered pallets, consider using a penetrating wood preservative first before staining or painting:
- Borate solutions – Borates penetrate wood and make it insect and fungus resistant. Brands like Tim-Bor.
- Wood oils – Oils like linseed soak into wood pores to limit moisture. Require reapplication.
- Wood preservatives – Solutions made for outdoor wood containing zinc naphthenate.
- Clear treatments – Solutions like benzalkonium chloride aid preservation without altering wood color.
Application tips:
- Use preservatives made for outdoor wood projects. Follow label safety precautions.
- Apply preservative liberally to all sides of wood with a brush or sprayer per product directions.
- Allow wood to dry fully before adding any finish stain or paint.
Use wood preservatives along with stains or paints for fortified protection and longevity. Reapply annually.
Using a Water-Repellent Wood Sealer
For finishing pallet projects that will live outdoors, consider applying a water-repellent wood sealant:
- Wood sealers – Sealants like Thompson’s WaterSeal are clear, water-resistant finishes.
- Tung oil – Penetrates deep while allowing wood to breathe. Provides water resistance. Reapply yearly.
- Teak oil – Contains oil, varnish, and mineral spirits for durability and UV protection.
- Boiled linseed oil – Made from flaxseed, provides a protective coating.
Application tips:
- Prepare wood by sanding smooth and removing any dust.
- Work evenly to apply a thin coat on all sides with a rag, brush, or sprayer.
- Allow 2-3 days drying time before reapplying additional coats.
- 3-4 applications provide superior protection.
Reapply water-repellent sealant every 1-2 years as needed.
Helpful Tips and Tricks
Follow these additional pointers for getting the longest possible life from outdoor pallet projects:
- Drill drainage holes if using pallets for planters so roots don’t sit wet.
- Add casters or glides to allow furniture to dry out underneath.
- Use exterior-grade screws, nails, and hardware rated for weather-resistance.
- Check for splintering, cracks, peels, mold, or mildew yearly and sand or seal as needed.
- Disassemble items like planters in winter if not frost-hardy or store indoors.
- Avoid placing pallet wood directly on damp ground or concrete. Use spacers.
- If sealing, coat ALL exposed surfaces – don’t miss undersides or inner faces.
- Reseal any cuts, holes, or new exposed areas immediately.
With the right weatherproofing and care, you can enjoy beautifully upcycled pallet creations outdoors for years of stylish durability. Get ready to impress your family and neighbors with your creative DIY pallet projects!
Frequently Asked Questions About Treating Pallet Wood for Outdoor Use
Can I use pallet wood outdoors without treating it?
It’s not recommended to use raw pallet wood for outdoor projects. Untreated wood will quickly warp, crack, rot, and degrade when exposed to rain, sun, snow, and other elements. Properly preparing and weatherproofing the wood is key for longevity outdoors.
How long does treated pallet wood last outside?
When properly cleaned, sealed, stained, painted or finished, pallet wood can last 2-5 years outdoors with proper maintenance. Harsh weather, moisture exposure, sun intensity, and usage levels impact lifespan. Expect to re-treat patio furniture yearly, while a pallet planter may last 2 years before needing a refresh.
What is food-safe pallet wood?
If you want to use reclaimed pallets for raised garden beds, planter boxes, compost bins, or other gardening projects, look for pallets stamped “food-safe”, usually on the center boards. This indicates no chemicals or fumigants were used that could leach into the soil.
Can I stain pallet wood different colors?
Yes, exterior wood stains are available in a wide variety of semi-transparent and solid colors. Opt for weatherproof tones like medium to dark browns, reds, greens, grays, and walnut. Avoid bold colors which fade quickly in sun. Always test stains first on scraps.
How do I get a smooth finish on rough pallet wood?
For a smooth surface for painting, lightly sanding the pallet boards first is key. Use 80-120 grit sandpaper to smooth any rough edges, splinters, and raised wood fibers. Wipe away sanding dust. Prime before painting for a professional look that hides wood grain.
What kind of paint should I use on pallets?
Exterior latex and oil-based paints are best for coating pallet wood used outdoors. Opt for mold/mildew resistant exterior paint. Primer helps paint adhere. Add textured paint for better grip on furniture or steps. Follow recoat times.
Can I use pallet wood for a raised garden bed?
Yes, pallet gardening boxes are a very popular DIY project! Be sure to use food-safe, heat-treated pallets free of chemicals. Line the inside with landscape fabric to keep soil contained. Stain or seal the wood so it holds up to weather exposure. Add casters to move it.
How do I fasten pallet boards securely?
Outdoor projects need weather-resistant fasteners. Use 2-3″ exterior-grade screws, or nails such as stainless steel, galvanized steel, or coated decking nails. Drill pilot holes to prevent wood from splitting. Follow best practices for wood joints using corner brackets, wood glue, etc.
Final Thoughts
With some simple preparation, weatherproofing, and regular upkeep, recycled pallet wood can be put to use in amazing outdoor structures like furniture, raised beds, storage boxes, shelving, and more. By properly cleaning, sealing, painting or staining your upcycled pallets, you can give them a long life outdoors and enjoy your handcrafted pieces for many years to come. Always inspect for damage before winter storage or severe weather. A small time investment in treating pallet wood pays off exponentially with projects built to endure the elements. Let your imagination run wild to create stylish, eco-friendly backyard projects showcasing the beauty and versatility of recycled pallet wood!