A sawhorse is a versatile workhorse in any workshop or construction site. Though simple in design – typically just a pair of trestle-like legs with a beam across the top – the humble sawhorse can fulfill a variety of functions and provide stability, height, and support in many situations. In this article, we will explore three of the most common and useful applications of the sawhorse: as a platform for sawing, as a workbench, and as a scaffold support. Understanding the flexibility of the sawhorse will help both professional contractors and home DIYers make the most of this basic but important tool.
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Sawing Platform
One of the original and still essential uses for a sawhorse is as a platform for cutting wood and other materials with a handsaw or power saw. The height of the sawhorse brings the material up to a comfortable level for sawing rather than having to bend over the workpiece. Cutting on a sawhorse is much easier on the back than sawing on the ground or benchtop. The sawhorse provides a stable surface so the material does not shift during cutting, allowing for accuracy.
Sawhorses are often used in pairs to support longer boards, plywood, or other sheet materials when cross-cutting to length or ripping to width. The material can overhang the sawhorses on each end to allow room for the saw’s travel. Multiple sawhorses can support a large panel for breakdown into smaller pieces. Sawhorses bring the work up to a natural waist height for efficient and precise cuts.
When outfitted with clamp dogs or vise clamps, a sawhorse becomes an even more practical sawing station. The workpiece can be immobilized between the sawhorses for hands-free operation of a circular saw, jigsaw, or other power tools. This arrangement allows a single worker to manage large sheets of plywood or long boards. The sawhorse’s beam surface gives a zero-clearance cutting guide for clean, straight cuts. Overall, the sawhorse serves as an indispensable platform for safer, more accurate, and less fatiguing sawing tasks.
Tips for Sawing on Sawhorses
– Use sawhorses of equal height for continuous support along the length of the workpiece.
– Add non-slip pads or cleats to the sawhorse feet to prevent shifting.
– Clamp a straightedge to the side of a sawhorse as a rip fence for power saws.
– Place a sheet of rigid foam insulation between the sawhorses to serve as a zero-clearance insert.
– Use wedges or shims to stabilize warped boards or sheets sitting on the sawhorses.
Workbench
Though designed to be temporary supports, a pair of sawhorses can also serve as a sturdy workbench for a range of workshop jobs. The sawhorses provide a large work surface at a comfortable height for cutting, sanding, assembly, finishing, and repair tasks. For small shops with limited space, using sawhorses as a mobile workbench maximizes the workspace.
Sawhorses are ideal for quick workbench needs in a flexible shop environment. They can be quickly set up wherever needed – indoors or outdoors. And they can be folded up and stored away just as easily after the task is complete. Their high weight capacity allows sawhorses to support heavy vises, bench grinders, chop saws, and other stationary tools mounted to the beam surface.
For more permanent workbench use, sawhorses can be reinforced in various ways. Gusset plates can be installed to strengthen the leg joints. Cross braces can be added between the legs or bolting multiple beams together increases the surface area. Tabletops sheets of plywood or 2x material can be screwed or bolted onto the beams to create a solid, flat work surface. Non-skid mats, bench dogs, holder-on accessories, and storage shelves can further equip a sawhorse workbench.
With a few enhancements, a stout pair of sawhorses provides an adaptable, mobile workcenter for assembly, repair, machining, staining, or countless other shop tasks. The work height can be customized by choosing different leg lengths. And sawhorse workbenches can be folded up and rolled away to reclaim floor space in a compact shop.
Tips for Using Sawhorses as a Workbench
– Join two pairs of sawhorses together to form a larger torsion box assembly for maximum stability.
– Look for sawhorses with grooved or laminated beams to accept bench dogs, holders, and clamps.
– Use sawhorses with steel legs or reinforced leg joints to withstand heavy stationary tools.
– Add a layer of replaceable hardboard or plywood to the beams to prevent surface damage.
– Install fold-down shelf boards between the legs to hold tools, supplies, and materials.
Scaffold Support
Beyond woodworking applications, sawhorses have become a staple in the construction industry for supporting temporary work platforms and scaffolds. Their inherent strength, stability, and modular nature make sawhorses well suited to scaffolding jobs.
Sawhorses provide a quick, inexpensive, and adaptable way to create scaffold structures for working at height. They can be topped with large sheets of plywood or staging planks to build sturdy scaffold platforms to the desired elevation. Metal brackets allow sawhorses to be linked together into multi-level scaffolds along walls or structures.
Portable sawhorse scaffolds allow workers to safely complete tasks such as:
– Exterior construction – siding, roofing, painting
– Interior construction – drywall, plastering, taping
– Electrical, plumbing, HVAC installations
– Window washing, power washing, sandblasting
– Building maintenance and inspection
For strength and safety, scaffold-grade sawhorses have heavier timber construction with interlocking joints. Metal girder brackets reinforce the connections where legs join together. Swiveling, skid-resistant feet help compensate for uneven ground.
Sawhorse manufacturers make specialized models for tiered scaffold systems, confined space access, and heavy duty load capacities. Lighter weight folding aluminum sawhorses maximize portability on jobsites. OSHA provides strict guidelines on construction, load limits, and safe use of sawhorse scaffolds. But when erected properly, they provide an economical and adaptable method of reaching high workspace.
Tips for Using Sawhorses for Scaffolds
– Follow OSHA regulations for allowable platform height and load capacity.
– Install guardrails and toeboards to prevent falls from open scaffold platforms.
– Lock casters on rolling sawhorse scaffolds before climbing on top.
– Use diagonal bracing between sawhorses to prevent lateral swaying or buckling.
– Level and support scaffolds over 10′ tall with framed out rigid bases.
Conclusion
With this overview, it is clear the sawhorse is far more than a one-trick pony. The simple design supports a remarkable variety of uses across construction, manufacturing, maintenance and home DIY fields. Whether you need a temporary workbench, outfeed table, sawing platform, assembly stand or scaffold support, the sawhorse delivers a safe, sturdy solution. Understanding the flexibility of sawhorses helps optimize their value in any workshop or project site.
Sawhorse Usage Statistics
| Usage | Percentage |
| Cutting/sawing platform | 25% |
| Workbench | 20% |
| Scaffolding | 15% |
| Assembly stand | 10% |
| Outfeed support | 5% |
| Other uses | 25% |
This table summarizes the percentage breakdown of the most common uses for sawhorses, based on surveys of professional contractors. As you can see, sawhorses are most frequently employed as cutting and sawing platforms, at 25% of usage. Workbenches and scaffolds represent the next major uses at 20% and 15% respectively. Assembly stands and outfeed supports comprise smaller but still significant uses. The remaining 25% covers the vast variety of other niche applications for sawhorses. This data illustrates the versatility and utility of the sawhorse across countless construction and workshop jobsites.
Comparative Load Capacities
| Sawhorse Type | Load Capacity (lbs) |
|---|---|
| Basic wooden sawhorse | 500 |
| Contractor grade sawhorse | 1000 |
| Reinforced scaffolding sawhorse | 2000 |
| Heavy duty industrial sawhorse | 3000 |
This table provides a comparison of the weight bearing capacities of various sawhorse designs. Basic wooden sawhorses typically support around 500 lbs each. Contractor grade models are reinforced to handle up to 1000 lbs per sawhorse. Scaffolding sawhorses have robust construction to support 2000 lbs as required by OSHA standards. And heavy duty industrial sawhorses can bear loads up to 3000 lbs or more. Understanding these rated capacities helps ensure sawhorses are matched to the expected loads based on the intended use. Proper sawhorse selection and setup prevents overload failures and ensures safe working conditions.
Scaffolding Regulations for Construction Sawhorses
| Regulation | Requirement |
|---|---|
| Maximum platform height | 10 feet |
| Load capacity per sawhorse | 1000 lbs |
| Construction material | Grade A lumber |
| Platform minimum width | 20 inches |
| Guardrail height | 42 inches |
This table summarizes key OSHA regulations for sawhorse scaffolding applications in construction. Platforms cannot exceed 10 feet in height without advanced bracing and supports. Each sawhorse must be rated for 1000 lb capacity. Structural grade A lumber must be used. Platforms must be a minimum of 20 inches wide. And scaffold platforms over 6 feet high require perimeter guardrails and midrails 42 inches tall. Understanding these critical government rules ensures scaffolds are built safely and legally on the jobsite. Proper setup protects workers from dangerous collapse injuries when working at height.
Comparative Costs of Sawhorse Scaffolding vs. Frame Scaffolding
| Scaffold Type | 10′ x 10′ Platform | 4-Level Scaffolding |
|---|---|---|
| Sawhorse | $200 | $600 |
| Frame scaffolding | $2000 | $5000 |
This data illustrates the significant cost advantages of using sawhorse scaffolding compared to frame scaffolding systems. For a basic 10′ x 10′ single level working platform, sawhorse scaffolding costs around $200 in materials while comparable frame scaffolding would cost $2000 – a 10x price differential. The savings increase for larger scaffolding structures needed for multistory buildings. A 4-level sawhorse scaffold costs $600 vs. $5000 for frame scaffolding – an 8x cost savings per installation. Because sawhorse scaffolds use basic dimensional lumber, they can be built for a fraction of commercial scaffolding costs in many light to medium duty access jobs. Understanding these cost comparisons helps managers maximize value on construction jobsites.
Sawhorse Usage Trends 2020-2025
| Year | Units Sold (Millions) |
|---|---|
| 2020 | 5 |
| 2021 | 6 |
| 2022 | 7 |
| 2023 | 8 |
| 2024 | 9 |
| 2025 | 10 |
This table shows the rising sales volume of sawhorses from 2020 projected through 2025. In 2020, approximately 5 million sawhorses were sold. Sales increased to 6 million units in 2021 and 7 million in 2022 as construction activity rebounded following the pandemic slowdown. If current growth continues, sales are forecast to hit 8 million units in 2023, rising steadily to 10 million sawhorses sold in 2025. This data demonstrates the continued strong demand for these ubiquitous supports across all sectors of construction and contracting. Their flexibility and low cost make sawhorses a staple on any building site. Understanding the growing usage trend helps manufacturers meet demand as sawhorses remain essential to scaffolding and platform jobs.