Offroad Pallet Jacks

Standard pallet jacks with their small polyurethane wheels struggle on anything but smooth concrete. Offroad pallet jacks—also called all-terrain or rough terrain pallet trucks—feature larger wheels, often pneumatic, designed to handle gravel, dirt, uneven concrete, and outdoor surfaces where conventional jacks fail.

When you need to move palletized loads across construction sites, lumber yards, farms, outdoor storage areas, or any surface rougher than a warehouse floor, offroad pallet jacks provide the capability. This guide compares options and helps you choose the right equipment for challenging surface conditions.

Why standard pallet jacks fail outdoors

Standard pallet jack limitations

Small wheels. 74-85 mm (2.9-3.3 in) diameter load wheels.
Hard material. Polyurethane or nylon designed for smooth floors.
Low clearance. Forks ride close to ground.
No suspension. Every bump transfers to operator and load.

What happens on rough surfaces

Wheels sink into soft material
Wheels catch on debris and uneven surfaces
Extreme effort required to push
Load instability on uneven ground
Rapid wheel wear and damage
Potential tip-over hazards

Types of offroad pallet jacks

Pneumatic wheel pallet jacks

Air-filled tires similar to bicycle or wheelbarrow tires.

Wheel size. 200-400 mm (8-16 in) diameter.
Tire type. Air-filled pneumatic.
Advantages. Cushioning, floats over obstacles, good traction.
Disadvantages. Can go flat, require inflation maintenance.
Capacity. Usually 500-1,500 kg (1,100-3,300 lb).
Best for. Outdoor use, gravel, dirt, grass.
Price. $600-1,500.

Semi-pneumatic wheel pallet jacks

Solid rubber tires with cushioning design.

Wheel size. 150-300 mm (6-12 in) diameter.
Tire type. Solid rubber with air pockets or cushion design.
Advantages. No flats, some cushioning, less maintenance.
Disadvantages. Less cushioning than true pneumatic.
Capacity. 500-2,000 kg (1,100-4,400 lb).
Best for. Rough concrete, occasional outdoor.
Price. $500-1,200.

Large wheel pallet jacks

Oversized polyurethane or nylon wheels.

Wheel size. 150-200 mm (6-8 in) diameter.
Tire type. Solid polyurethane or nylon.
Advantages. No flats, rolls over small obstacles.
Disadvantages. Limited cushioning, still struggles on very rough ground.
Capacity. 2,000-2,500 kg (4,400-5,500 lb).
Best for. Rough warehouse floors, dock plates.
Price. $400-900.

All-terrain powered pallet jacks

Electric or engine-powered units with offroad capability.

Power. Electric or gasoline.
Wheels. Large pneumatic or semi-pneumatic.
Advantages. Power assist for heavy loads on rough ground.
Capacity. 1,000-3,000 kg (2,200-6,600 lb).
Best for. High volume outdoor operations.
Price. $5,000-15,000+.

Key specifications comparison

Specification	Standard	Pneumatic	Semi-Pneumatic
Load wheel diameter	74-85 mm	200-400 mm	150-300 mm
Steer wheel diameter	160-200 mm	250-400 mm	200-300 mm
Ground clearance	Low	High	Medium
Capacity typical	2,000-2,500 kg	500-1,500 kg	1,000-2,000 kg
Rolling effort on rough	Very high	Low	Medium
Maintenance	Low	Higher (inflation)	Low
Price	$300-600	$600-1,500	$500-1,200

Surface suitability

Surface capability comparison

Surface	Standard	Large Wheel	Semi-Pneumatic	Pneumatic
Smooth concrete	Excellent	Excellent	Excellent	Good
Rough concrete	Poor	Good	Good	Excellent
Asphalt	Fair	Good	Good	Excellent
Gravel	Poor	Fair	Fair	Good
Packed dirt	Poor	Fair	Good	Excellent
Grass	Poor	Poor	Fair	Good
Loose sand/soil	No	No	Poor	Fair

Applications

Construction sites

Material delivery to job sites
Moving supplies across rough ground
Temporary storage areas

Lumber yards

Outdoor lumber storage
Gravel or packed dirt surfaces
All-weather operation

Agriculture

Farm supply handling
Feed and seed pallets
Barn and outdoor storage

Garden centers and nurseries

Outdoor display areas
Gravel pathways
Uneven terrain

Event and tent operations

Outdoor event setup
Equipment on grass
Temporary surfaces

Industrial outdoor storage

Outdoor storage yards
Overflow areas
Loading areas without pavement

Capacity considerations

Reduced capacity on rough terrain

Offroad conditions affect practical capacity:

Rated capacity assumes level, stable surface
Slopes reduce safe capacity significantly
Soft surfaces reduce effective capacity
Uneven loads more problematic on rough ground

Capacity guidelines

Reduce rated capacity by 20-30% for rough surfaces
Reduce further for slopes
Center loads carefully
Use lower capacity if surface is uncertain

Selection guide

Choose pneumatic when

Primary use is outdoor/rough terrain
Surfaces include gravel, dirt, grass
Maximum cushioning needed
Loads are moderate (under 1,500 kg)
You can maintain tire inflation

Choose semi-pneumatic when

Mix of indoor and outdoor use
Rough but mostly hard surfaces
No-flat operation is important
Higher capacity needed
Minimal maintenance preferred

Choose large wheel standard when

Primary use is indoors
Occasional rough floor or dock plate
Maximum capacity needed
Budget is limited

Maintenance

Pneumatic tire maintenance

Check tire pressure weekly
Maintain manufacturer-specified PSI
Inspect for punctures and damage
Keep spare tubes/tires on hand
Replace worn tires promptly

General maintenance

Clean debris from wheels and forks
Check hydraulic system regularly
Lubricate pivot points
Inspect for structural damage from rough use

See our pallet jack maintenance guide for details.

Pricing comparison

Type	Price Range
Large wheel (solid)	$400-900
Semi-pneumatic	$500-1,200
Pneumatic (manual)	$600-1,500
All-terrain powered	$5,000-15,000+

Top manufacturers

Vestil. Multiple offroad options.
Wesco. All-terrain models available.
Noblelift. Rough terrain options.
Pramac. Pneumatic wheel models.
Hu-Lift. Various wheel configurations.