Repairable plastic pallet with removeable support blocks and associated methods

A support block for a pallet comprising:

• an inner wall surrounding an interior opening,
• at least one cap surface positioned to cover a portion of the interior opening,
• an outer wall surrounding said inner wall,
• a plurality of ribs extending between said inner and outer walls,
• a plurality of aligned lower tabs extending outwards from lower surfaces of the plurality of ribs,
• a first plurality of upper tabs extending outwards from upper surfaces of said inner wall, with each of the first plurality of upper tabs comprising a first contact surface for engaging the top deck, and
• a second plurality of upper tabs extending outwards from the upper surfaces of said inner wall, with each of the second plurality of upper tabs comprising a second contact surface for engaging the top deck,
• wherein the first and second contact surfaces for engaging the top deck face away from each other.

A method for making a pallet comprising:

• forming a top deck having spaced apart upper and lower surfaces;
• forming a bottom deck;
• and
• coupling a plurality of spaced apart support blocks coupled between the top and bottom decks and forming an opening therebetween, each support block comprising:
• an inner wall surrounding an interior opening,
• at least one cap surface positioned to cover a portion of the interior opening,
• an outer wall surrounding said inner wall,
• a plurality of ribs extending between said inner and outer walls,
• a plurality of aligned lower tabs extending outwards from lower surfaces of the plurality of ribs,
• a first plurality of upper tabs extending outwards from upper surfaces of said inner wall, with each of the first plurality of upper tabs comprising a first contact surface for engaging the top deck, and
• a second plurality of upper tabs extending outwards from the upper surfaces of said inner wall, with each of the second plurality of upper tabs comprising a second contact surface for engaging the top deck,
• wherein the first and second contact surfaces for engaging the top deck face away from each other.