Not every business has the luxury of indoor pallet storage. If you're keeping pallets outside — whether temporarily or long-term — proper storage practices make the difference between pallets that stay in good condition and pallets that deteriorate prematurely.
Choose the Right Surface
Never store pallets directly on bare ground. Moisture wicking up from soil is one of the fastest ways to cause rot, mold, and structural degradation. Place pallets on:
- Concrete or asphalt: The best option. Hard, relatively dry surfaces that minimize moisture contact.
- Gravel: Acceptable alternative. Provides drainage and keeps pallets elevated above standing water.
- Plastic sheeting over compacted ground: A budget option that creates a moisture barrier.
Elevate the Base
Even on concrete, place a sacrificial layer of pallets or concrete blocks at the base. This creates airflow beneath your inventory and prevents the bottom pallets from absorbing ground moisture. Consider these base pallets as permanent infrastructure, not part of your rotating stock.
Cover Your Inventory
Rain, snow, and even heavy dew will accelerate pallet deterioration. Cover outdoor pallet stacks with:
- Waterproof tarps: Affordable and effective. Secure with bungee cords or weights to prevent wind displacement.
- Corrugated plastic sheeting: More durable than tarps and provides better rain shedding. Worth the investment for permanent outdoor storage.
- Simple lean-to structures: If you have significant outdoor pallet inventory, a basic pole-and-roof structure pays for itself in reduced pallet replacement costs.
Important: Don't wrap covers tightly around the sides. Air circulation is critical — trapped moisture is worse than rain exposure. Cover the top and let the sides breathe.
Stack Properly
Outdoor stacking rules are similar to indoor, with some additions:
- Limit stack height to 6 feet maximum for empty pallets in outdoor conditions
- Stack pallets nesting — alternating orientation isn't necessary for empty pallets and actually increases wind resistance
- Ensure stacks are level. Leaning stacks in windy conditions are a safety hazard
- Leave space between stacks for airflow and access
Rotate Your Stock
Practice FIFO (First In, First Out) with outdoor pallets. Pallets that have been sitting outside longest should be used first to prevent any inventory from spending excessive time exposed to the elements. Mark arrival dates with chalk or weather-resistant markers.
Regular Inspection
Check your outdoor pallet inventory at least monthly for:
- Signs of mold or fungal growth
- Warping or cupping from moisture exposure
- Insect activity (especially in warmer months)
- Structural degradation
Catch problems early and rotate affected pallets to indoor use or repair before they become unsalvageable.
Seasonal Considerations
In North Carolina, our humid summers and occasional winter ice storms present different challenges. Summer: focus on mold prevention and insect control. Winter: focus on moisture management and stack stability during ice events. Spring and fall are your best times for deep inventory inspections.
Proper outdoor storage isn't complicated, but it does require attention. A few simple practices can extend the life of your pallet inventory significantly.