Hardwood Floors August/September 2025

By Brett Miller

THE HANDLE The most common material used for mallet handles is hickory, prized for its superior strength-to-weight ratio and exceptional shock absorption. This is the same reason hickory long has been favored for baseball bats. During floor installation, repeated impact creates significant vibration which can lead to health issues such as strains, tendinitis, and even carpal and cubital tunnel syndrome. Hickory helps dampen this shock, reducing fatigue for the installer and improving control. While less traditional, fiberglass handles also are used and offer notable advantages. Unlike wood, fiberglass won’t split, making it a durable alternative option. However, it does not absorb vibration as well as hickory, and some professionals find

THE HEAD The mallet head is constructed typically from either cast iron or aluminum, with each material tailored to specific needs. Cast iron heads, normally available in 3-pound and 5-pound options, deliver more driving force and often are preferred by flooring professionals in heavier-duty installation applications. Aluminum heads, commonly found in lighter weighted, 1½-pound mallets, provide handling ideal for pneumatic nailers that require only a light tap to activate the plunger. Regardless of the type of metal used, the head is designed with a tapered end and a rubber end that allows the installer to drive the boards tight while reducing the likelihood of damage to the face of the wood plank.

PHOTOS COURTESY OF NWFA

fiberglass handles transmit more impact to the wrist and elbow. The length of the handle varies depending on the ergonomics of the tools. The manufacturer of the mallet normally pairs the length of the handle with the nailer it is used with. A lower profile nailer will require a longer handle, while a nailer that is positioned higher will require a shorter handle. Some installers even cut their handles to a comfortable position for their stature. Regardless of material, design, or length, most handles feature grip enhancing dimples or textures, or even over-lay grips that help the installer maintain a secure hold of the mallet during floor installation. Ergonomics and grip design are essential considerations for tool performance and user safety.

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