Guide / Repairs
Plugs, plates and repairs
A plug is a short board nailed beside a cracked stringer, a plate is a metal fastening across a split, and a replaced deck board is a new board on a sound frame. All three make a Grade B pallet.
The three repairs
| Repair | What it fixes | Notes |
|---|---|---|
| Plug | A cracked or split stringer | A short board nailed beside it; between 6 and 24 inches long |
| Plate | A split across a board or stringer | A metal fastening that holds the wood together |
| Replaced board | A broken or missing deck board | Newer wood that shows against older boards |
Repairs are why Grade B is cheaper than Grade A and why it is still sound. Millwood's guide counts repaired stringers or plugs greater than 1 1/4 inches as Grade B features.
When a repair is not enough
A pallet with several broken stringers, rot, or loose deck boards goes toward dismantling instead. Good boards are reused in rebuilt combo pallets, and what remains is ground. How many plugs a pallet can carry before it is Grade C is a judgment call, and buyers differ. If you hold a pile of repaired stock, a photo of a few typical pallets helps more than a description.
Why it matters to a request
Sellers: say how many pallets carry plugs and whether plugs sit near fork pockets, where a lift might catch. Buyers: say whether visible repairs are acceptable. See Grade B, and pallet cores for the recycler's side.
Inspecting a repaired pallet
A good repair is flush, tight and made with the right fasteners. A poor one has bent nails, split wood or a plate with loose fixings. Run your hand along the repaired area; sharp points mean it should be rejected. A plate that rocks in place is a plate that will fall off.
Judging how many repairs are too many
Repair technique matters less than count. A pallet with one plate over a split board is fine. A pallet with plates, plugs and replacement boards in a dozen places has been through many cycles and may have little life left. As a rule of thumb, if repairs outnumber original boards, the pallet is a candidate for the core pile.
Plugs fill holes where a block or stringer has chipped, and plates, usually steel, bridge cracks in stringers. Both give back strength without replacing the part. Nails are chosen to match the wood, and a repair made with the wrong nail will loosen under vibration.
When you buy repaired pallets, look at the pattern. Repairs spread evenly across a batch are a sign of an organised operation; scattered or messy ones suggest otherwise. Ask to see a sample from the middle of the stack.
A repair shop that logs its work can tell you how many cycles each pallet has seen.