Video - January 10, 2025
Looking for a great way to store plywood in a small shop space? Check this out!
Handling sheet goods like plywood and MDF can be a daunting task, especially as we age or deal with back issues. These materials are essential for many projects due to their stability and cost-effectiveness, but purchasing, transporting, and maneuvering them around your shop can be a real challenge. In this article, I’ll share my approach to managing plywood, from picking it up and transporting it to cutting it down, with back safety in mind.
As much as I appreciate the value of plywood and MDF, the process of handling these large, heavy panels can strain your body—particularly your back. If you suffer from acute or chronic back issues, lifting and moving sheet goods improperly can worsen your condition. That’s why it’s important to have strategies in place to avoid unnecessary stress and strain. While this is not medical advice, the techniques I use help minimize the impact on my back, and I hope you can apply some of these methods to suit your own needs.
Before you even leave for the lumber yard, take a few simple precautions to ensure a smoother process:
When it comes to transporting sheet goods, a pickup truck is my vehicle of choice. Most lumber yards will assist with loading, but always ask if you’re unsure. I prefer to load the plywood with the tailgate up to let gravity help hold the sheets in place. For larger loads, I use ratchet straps to secure the sheets and prevent them from shifting during transport.
Once you’re back in your shop, unloading and moving plywood requires thoughtful technique:
A common piece of advice is to cut sheet goods on an elevated surface to avoid straining your back. While this may work for some, I personally find cutting on the floor much easier and less taxing on my body. By keeping the plywood close to the ground, I have better control of my body position and the saw, which minimizes stress on my back. Of course, if you have knee problems, this method may not work for you. In that case, knee pads can help cushion your knees while you work.
There are various tools and gadgets designed to make handling plywood easier, but many rely on the sheet being laid flat in a horizontal position. I prefer to keep my plywood vertical as much as possible, but if you do need horizontal storage, some options include:
For those with limited space or just looking for ways to streamline their workflow, using a plywood cart from brands like Rockler or Festool can be a game-changer. These carts elevate the plywood, making it easier to handle. However, if you don’t need the elevation, these carts might not be as helpful.
In my setup, I rely on cutting tracks to break down larger sheets into smaller, more manageable pieces, which I then bring to my table for final assembly. This method keeps things efficient and reduces the risk of injury.
Handling sheet goods doesn’t have to be a back-breaking task. With the right strategies and techniques, you can safely transport, move, and cut plywood and MDF without putting undue strain on your body. Whether you prefer cutting on the floor or using a cart, the key is to find a system that works for you. If you have similar health concerns, I hope some of these tips help make your shop work a little easier and safer.
And if you have other tips for managing sheet goods with health concerns in mind, I’d love to hear about them in the comments!
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