Paper 2: Safety Engineering

UNIT IV: Hand tools and Portable tools

Causes of common hand tool injuries

The most common causes of hand tool accidents are:
 Carelessness
 Lack of awareness
 Boredom
 Disregard for safety procedures
 Distractions
 improper use
 improper maintenance of the hand tool
 Poor housekeeping

Types of hand tool injuries:

The following are the types of injuries that are caused by a hand tools.
1. Cuts, abrasions, amputations punctures. If hand tools are designed to cut or move metal
and wood, remember what a single slip can do to fragile human flesh.
2. Repetitive motion injuries. Using the same tool in the same way for several hours each
day, day after day, can stress human muscles and ligaments. Carpal tunnel syndrome
(inflammation of the nerve sheath in the wrist) and injuries to muscles, joints and ligaments are
increasingly common if the wrong tool is used, or the right tool is used improperly. Injury from
continuous vibration can also cause numbness or poor circulation in hands and arms.
3. Eye injuries. Flying chips of wood or metal are a common hazard; often causing needless
and permanent blindness.
4. Broken bones and bruises. Tools can slip, fall from heights or even be thrown by careless
employees, causing severe injuries. A screwdriver that falls from a ladder is a lethal weapon.

Control of hand tool accidents:

Some ways to avoid hand tool injuries include:
 Use the right tool for the job. Some examples of misuse of tools are using a wrench as a
hammer, pliers as a wrench, knife as a saw, claw hammer as a ball peen hammer,
screwdriver as a chisel, etc.
 Ensure you have the correct size tool, such as correct screwdriver, pliers, wrench,
scissor, etc.
 Individuals using the tool should be trained in the basic safety and proper use of the tool.
 Keep tools in good condition. Broken or worn tools (i.e. wrenches with cracked or worn
jaw, electric tools with broken plugs, etc.) should be repaired or discarded immediately.
Report defective equipment to your supervisor.
 Use tools the way they were intended (i.e. drive a wood chisel outward and away from
your body).
 When using a knife, cut away from the body and keep hands and body clear of knife
stroke.

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  Be cautious of tools around electrical equipment. Only trained and qualified individuals
may work on electrical equipment.
 Store tools in a safe place. Many accidents have been caused by tools falling from
overhead, and by sharp tools carried in pockets or left in toolboxes with the cutting
edges exposed. Ensure the tool is put away in the proper place after use and that sharp
edges or blades are protected or enclosed to prevent contact.
 Ensure tool handles are wedged tightly in the head of all tools.
 Hand tools such as chisels and punches, which develop mushroomed heads during use,
must be reconditioned or replaced as necessary.
 Keep tool cutting edges sharp so the tool will move smoothly without binding or skipping.
Dull tools can be more hazardous than sharp tools.
 When using hand tools, maintain a good grip and stand in a balanced position to avoid
sudden slips.
 Wear gloves when necessary to protect your hands. However, be cautious of gloves
and/or loose materials when using powered tools where they could get caught in a
moving part.
 Wear other personal protective equipment as warranted such as eye, face, and hearing
protection, respirators, appropriate shoes, etc.
 Keep wood handles free of splinters and cracks.
 Wrenches should not be used if jaws are sprung or loose.
 When using hand tools, ensure area around your work is clean, dry, well lit and free of
obstructions when possible.
 When using a screwdriver, do not hold an object in one hand and press a screwdriver
into it, place it on a bench or a table.
 Be cautious of spark-producing hand tools when working near flammable materials. Use
non-sparking tools when necessary.
 Consider ergonomically designed tools to fit the tool to the worker -- especially those
tools that are utilized frequently and repetitively during the day.
 Inspect your tools before each job to ensure proper condition.

Storage:
The following precautions to be taken while storing the hand tools:
 When the hand tools are not being used, keep them in assigned places where they won’t
be damaged by other tools. 
 Store cutting tools where their sharp edges won’t be blunted,
 Store cutting tools where they won’t damage other tools or your fingers.
 To prevent rust, store tools in a dry place and spray a rust-inhibiting coating on steel
tools or put a few packets of clay or silicone desiccant in the toolbox or cabinet.
 Store the cutting tools duly cleaned. After use, remove any sap or resins from cutting
tools (by using kerosene or ammonia before storage.
 Always put tools away at the end of a job and keep them under lock and key.

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Maintenance of Hand Tools:
To be safe and effective, hand tools must be kept in serviceable condition. Improperly
maintained tools are a hazard to the user and anyone working nearby. Proper care and
maintenance of hand tools will help prevent injuries to employees and will assist them in
working more efficiently. Keep tools clean. After use, remove any sap or resins from cutting
tools (by using kerosene or ammonia).

Use a tack rag. Dampen a piece of cloth slightly with a mix of turpentine and shellac. It will wipe
away oily sawdust from blades, housings, and other parts of hand and power tools. Store the
rag in a sealed jar or plastic bag for future use.

Rust is prevented in two ways: one, by keeping the tools dry (that means out of the rain and in
dry storage areas); and, two, by applying a light film of machine oil wiped on with a cloth. If
workshop is in a cellar, garage, or another damp space, consider buying a dehumidifier to
reduce the humidity in the area. However, if workshop is only occasionally wet and don’t have a
dry alternative, try storing tools in a tight toolbox, perhaps one made of plastic. Add weather
stripping, if necessary, and moisture absorbent. For power tools with steel surfaces, a paste
wax coating is easy to apply and helps prevent rust.

Selection of Hand Tools:

(Ref: A guide to selecting of non powered hand tools)
Hand tools are widely used in a variety of industries including construction, manufacturing, and
agriculture. The industrial accident data suggests that a large number of injuries known as
musculoskeletal disorders are attributable to hand tool use in occupational settings, resulting in
unnecessary suffering, lost workdays, and economic costs. Prevention of work-related
musculoskeletal disorders is a high priority in selecting a hand tool.
It is important to emphasize on design and selection of hand tools in strategies to reduce
injuries. Select the tools that can be used effectively with less force, less repeated movement,
and less awkward positioning of the body. These principles are meant to complement the
ordinary process of deciding on what tool to select by knowing how it is used and the task to
which it will be applied. We have to select tools that get the job done more safely, comfortably,
and productively.

The best tool is one that:

• Fits the job you are doing
• Fits the work space available
• Reduces the force you need to apply
• Fits your hand
• Can be used in a comfortable work position

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Symptoms of using a improper tool:
If any of these symptoms are found in a worker while using a hand tools then it is to be treated
that the hand toll is not proper for the job
• Tingling
• Swelling in the joints
• Decreased ability to move
• Decreased grip strength
• Pain from movement, pressure, or exposure to cold or vibration
• Continual muscle fatigue
• Sore muscles
• Numbness
• Change in the skin color of your hands or fingertips
These symptoms may not appear immediately because they develop over weeks,
months, or years. By then, the damage may be serious. Action is to be taken before
noticing any symptoms.

Guidelines for selecting a hand tool:

 Know your job
 Look at your work space
 Improve your work posture
 Review the “Tips for Selecting Hand Tools” and then Select the Tool

Know your job: Before selecting a tool, we shall think about the job we’ll be doing. Tools are
designed for specific purposes. Using a tool for something other than its intended purpose often
damages the tool and could cause us pain, discomfort, or injury. We can reduce our chances of
being injured when we select a tool that fits the job we will be doing.

Look at work space: We have to study the work space. Awkward postures may cause us to
use more force. We have to select a tool that can be used within the space available. For
example, if we work in a cramped area and high force is required, we shall select a tool that is
held with a power grip.
A pinch grip will produce much less power than a power grip. Exerting force with a pinch grip
means we shall work harder to get the job done.
If we work in a cramped space, we may not be able to use a long-handle tool. Use of a long-
handle tool may cause awkward postures or harmful contact pressure on hand as we use more
force. Instead, we shall use a tool that fits within the work space. A short-handle tool can help us
to reach our target directly as we keep our wrist straight.

Improve your work posture: Awkward postures make more demands on our body. In some
cases, the placement of the work piece will affect our shoulder, elbow, wrist, hand, or back
posture. Whenever possible, we have to choose a tool that requires the least continuous force
and can be used without awkward postures. The right tool will help us to minimize pain and
fatigue by keeping neck, shoulders, and back relaxed and arms at our sides.

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For example, we have to avoid raising shoulders and elbows. Relaxed shoulders and elbows
are more comfortable and will make it easier to drive downward force.

Select the tool: Over time, exposure to awkward postures or harmful contact pressures can
contribute to an injury. We can reduce our risk of injury if we select hand tools that fit our hand
and the job we are doing.

Tips for Selecting Hand Tools

 Tools used for power require high force. Tools used for precision or accuracy require
low force.
 Tool with sleeve: For single handle tools used for power tasks: Select a tool that feels
comfortable with a handle diameter in the range of 1 1/4 inches to 2 inches. You can
increase the diameter by adding a sleeve to the handle.
 For single-handle tools used for precision tasks: Select a tool with a handle diameter of
1/4 inch to 1/2 inch.
 For double-handle tools (plier-like) used for power tasks: Select a tool with a grip span
that is at least 2 inches when fully closed and no more than 3 1/2 inches when fully
open. When continuous force is required, consider using a clamp, a grip, or locking
pliers.
 For double-handle tools (plier-like) used for precision tasks: Select a tool with a grip
span that is not less than 1 inch when fully closed and no more than 3 inches when fully
open.
 For double-handled pinching, gripping, or cutting tools: Select a tool with handles that
are spring-loaded to return the handles to the open position.
 Select a tool without sharp edges or finger grooves on the handle.
 Select a tool that is coated with soft material. Adding a sleeve to the tool handle pads the
surface but also increases the diameter or the grip span of the handle
 Select a tool with an angle that allows you to work with a straight wrist. Tools with bent
handles are better than those with straight handles when the force is applied horizontally
(in the same direction as your straight forearm and wrist)
 Tools with straight handles are better than those with bent handles when the force is
applied vertically
 Select a tool that can be used with your dominant hand or with either hand.
 For tasks requiring high force: Select a tool with a handle length longer than the widest
part of your hand – usually 4 inches to 6 inches. Prevent contact pressure by making
sure the end of the handle does not press on the nerves and blood vessels in the palm
of your hand.
 If the handle is too short, the end will press against the palm of your hand and may
cause an injury.
 Select a tool that has a non-slip surface for a better grip. Adding a sleeve to the tool
improves the surface texture of the handle. To prevent tool slippage within the sleeve,
make sure that the sleeve fits snugly during use.
 Note: A sleeve always increases the diameter or the grip span of the handle

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Other factors to be considered while Selecting Hand Tools
Poorly designed hand tools too heavy, poorly balanced, with a grip that is too large, the wrong
shape, or slippery can lead to injuries of the hand, wrist, forearm, shoulder, and neck. Hammers
or pliers with bent handles keep the wrist and forearm straight to reduce injury and increase
power. Pliers and cutting tools with spring-assisted jaws require less finger and hand effort to
repeatedly open the jaws. Power tools with foam or rubberized grips help reduce the transfer of
vibration to the hands and arms.

Handle size: The right-sized handle is one that allows the hand to go more than halfway around
the handle without the thumb and fingers meeting.
The recommended grip diameter in most cases falls between 50 and 60 mm. To provide good
control of the tool and prevent pain and pressure hot spots in the palm of the hand, handles
should be at least 120 mm long. A precision grip (when the tool is pinched between the tips of
the thumb and fingers) is primarily used for work that requires control rather than a lot of force.
Handles for precision tools should be 8 to 13 mm in diameter and at least 100 mm long.

Grip surfaces: The grip surfaces of hand tools should be smooth, non-conductive, and slightly
compressible to dampen vibration and better distribute hand pressure. Avoid tools that have
grooves for finger — for most people the grooves are either too big or too widely or closely
spaced. The resulting pressure ridges across the hand can damage nerves or create hot spots
of pain. Grooves along the length of the handle are intended to prevent slipping but can also cut
into the hand and create pressure ridges, particularly if the tool is in continuous use. If a
grooved handle is the only choice available, ensure that the grooves are many, narrow and
shallow. If it is available, try a grip shape that is non-cylindrical. Triangular grips measuring
approximately 110 mm around at their widest part can be quite comfortable and help to increase
power.

Weight: Weight is often a problem with power tools and tools such as axes, hammers, and
saws. To reduce hand, arm, and shoulder fatigue, the hand tool should not weigh more than 2.3
kg. If the centre of gravity of a heavy tool is far from the wrist, this maximum weight should be
reduced. Studies have shown that tools weighing 0.9 to 1.75 kg feel “just right” for most
workers. For precision work where the small muscles of the hand support the tool, it should
weigh far less. Lighter is better. Heavy tools can be made easier to use by suspending or
counter weighting them. Avoid tools that have grooves for fingers. Heavy tools can be made
easier to use by suspending or counter weighting them.

Triggers: Many power tools have a trigger that is operated either by the thumb or one or more
fingers. To avoid hand and forearm fatigue, look for tools that can be activated by either hand.
Also, the trigger should have a mechanism that holds or locks it in place while the tool is being
used. Triggers should be at least 25 mm long for single-finger activation and 50 mm long for
two-finger activation. Use four-finger activation only with suspended tools.

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Characteristics to avoid when selecting a hand tool:
 Sharp edges and corners on tool handles
 Narrow handles, which concentrate large forces into small areas of the hand
 Smoot or highly polished handles or handles with recesses that fit only one size of hand
 Sharply curved handles-The curvature should be less than 0.5 inches over its length
 Scissors and shears with finger loops that cause excessive poressure on the thumb and
fingers(if possible, use power cutter instead)
 Tools that require workers to use a pinch or precision grip
 Short tool handles that press into the palm of the hand

Inspection and Repair of hand tools:

 Tools should be inspected by a person qualified through training and experience to
determine the safe condition of the tool.
 Worn or damaged tools should be tagged “DEFECTIVE –DO NOT USE” and returned to
the shop for repair or replacement.
 Regular inspection of all tools is necessary and should cover tool maintenance and
service as outlined in the operator’s manual.
 Observing proper handling and storage of tools should also be a part of the inspection
process.
 Responsibility for inspection is usually of the supervisor. However, tools should be
checked by those who use them daily.
 Hand tools that get the heaviest use and abuse, such as chisels, hammers, and
wrenches, should be inspected frequently and regularly.
 To maintain and repair tools properly requires the right facilities and equipment. A good
workbench, repair tools, vises, and good lighting are necessities. Only persons skilled in
the repair of tools should be allowed to do the repairs. Otherwise tools should be sent
out to a qualified repair depot.

Inspection and repair of power hand tools:

 Frequent inspection of power tools is essential to keep hazards from developing.
 Inspection will help to identify operating defects and possibly avoid costly breakdowns.
 A regular schedule for inspection — daily, weekly, or monthly depending on
requirements — will help to ensure that all power tools are in safe operating condition.
 Defective tools should be removed from service, tagged, and be either repaired or
replaced.
 Workers should be trained to inspect the tools they use and to report defects to their
supervisor.
 The extent of the inspection and the responsibility for maintenance or repairs must be
clearly communicated so that there is no misunderstanding.
 Workers should not carry out makeshift repairs.

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The safe practices that mechanics should follow when using new portable power tools
include the following:
 Store power driven tools in secured places.
 Do not leave them in areas where they may be struck by passersby or be otherwise
activated.
 Keep work areas heated, clean, and well lit.
 Secure, or clamp, work pieces.
 Normal tool use does not require a great deal of force.
 When working on a ladder, a scaffold, or in other high places, do not reach out too far.
Keep the body in balance.
 Wear proper clothing for the job. Loose clothing, jewelry, and long hair may add risk to
the job.
 Never use a power tool with a malfunctioning switch or part. Remove it from service, and
repair or discard the tool. Only use accessories recommended by the manufacturer

Safety in using power tools:

1. Pneumatic power tools.
 Pneumatic power tools shall be secured to the hose or whip by some positive means to
prevent the tool from becoming accidentally disconnected.
 Safety clips or retainers shall be securely installed and maintained on pneumatic impact
(percussion) tools to prevent attachments from being accidentally expelled.
 All pneumatically driven nailers, staplers, and other similar equipment provided with
automatic fastener feed, which operate at more than 100 p.s.i. pressure at the tool shall
have a safety device on the muzzle to prevent the tool from ejecting fasteners, unless
the muzzle is in contact with the work surface.
 Compressed air shall not be used for cleaning purposes except where reduced to less
than 30 P.S.I and then only with effective chip guarding and personal protective
equipment which meets the national standards.
 The manufacturer’s safe operating pressure for hoses, pipes, valves, filters, and other
fittings shall not be exceeded,
 The use of hoses for hoisting or lowering tools shall not be permitted.
 All hoses exceeding 1/2 inch inside diameter shall have a safety device at the source of
supply or branch line to reduce pressure in case of hose failure.
 Airless spray guns of the type which atomize paints and fluids at high pressures (1,000
pounds or more per square inch) shall be equipped with automatic or visible manual
safety devices which will prevent pulling of the trigger to prevent release of the paint or
fluid until the safety device is manually released.
 In lieu of the above, a diffuser nut which will prevent high pressure, high velocity release,
while the nozzle tip is removed, plus a nozzle tip guard which will prevent the tip from
coming into contact with the operator, or other equivalent protection, shall be provided.
 Abrasive blast cleaning nozzles. The blast cleaning nozzles shall be equipped with an
operating valve which must be held open manually. A support shall be provided on
which the nozzle may be mounted when it is not in use.

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2. Fuel powered tools.
 All fuel powered tools shall be stopped while being refueled, serviced, or maintained,
and fuel shall be transported, handled, and stored in accordance with national standard
 When fuel powered tools are used in enclosed spaces, the applicable national standar
requirements for concentrations of toxic gases and use of personal protective equipment
shall apply.

3. Hydraulic power tools.

 The fluid used in hydraulic powered tools shall be fire-resistant fluids, and shall retain its
operating characteristics at the most extreme temperatures to which it will be exposed.
 The manufacturer’s safe operating pressures for hoses, valves, pipes, filters, and other
fittings shall not be exceeded.

4. Power-actuated tools.
 Only employees who have been trained in the operation of the particular tool in use shall
be allowed to operate a powder-actuated tool.
 The tool shall be tested each day before loading to see that safety devices are in proper
working condition. The method of testing shall be in accordance with the manufacturer’s
recommended procedure.
 Any tool found not in proper working order, or that develops a defect during use, shall be
immediately removed from service and not used until properly repaired.
 Personal protective equipment shall be in accordance with national standard.
 Tools shall not be loaded until just prior to the intended firing time. Neither loaded nor
empty tools are to be pointed at any employees. Hands shall be kept clear of the open
barrel end.
 Loaded tools shall not be left unattended.
 Fasteners shall not be driven into very hard or brittle materials including, but not limited
to, cast iron, glazed tile, surface-hardened steel, glass block, live rock, face brick or
hollow tile.
 Driving into materials easily penetrated shall be avoided unless such materials are
backed by a substance that will prevent the pin or fastener from passing completely
through and creating a flying missile hazard on the other side.
 No fastener shall be driven into a spalled area caused by an unsatisfactory fastening.
 Tools shall not be used in an explosive or flammable atmosphere.
 All tools shall be used with the correct shield, guard, or attachment recommended by the
manufacturer.

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Maintaining Portable Electric Power Tools

It is important that the right portable electric power tools be available when needed. However,
this is of no value if the tools are not in good working order and able to effectively and safely
perform the work.

Portable electric power tools not maintained and in good working order are first and foremost
safety hazard. Secondly, poorly maintained portable electric power tools will affect both the
productivity and morale of those using them. The cost of providing adequate and well-
maintained portable electric power tools to field personnel is small compared to the cost of lost
productivity or a resulting accident.

Where does good tool maintenance start?

Good tool maintenance starts with the proper use of tools at the work site. Field personnel must
know how to select the right tool for the job and then understand how to use it properly. Training
in proper selection and use of these tools is the key to trouble free use and long tool life.

Manufacturers design portable electric power tools for specific applications and, like any piece
of equipment, they have their limitations. Using the wrong tool for a job can result in damage to
the tool and/or injury to the user. Attempting to use a tool beyond its rating or for a job it was not
designed for is begging for trouble. Misapplying and overloading a portable electric power tool
may result in damage to its electric drive motor and its mechanical mechanism.

Selecting the right tool for the job is only the first step. Using these portable electric power tools
properly is equally as important. Tools must be used in accordance with manufacturer
recommendations and instructions. This includes the use of personal safety equipment such as
safety glasses, hearing protection, and other protective clothing and accessories.

Users should read and follow any operating instructions provided with the portable electric
power tool and heed any warnings or directions stamped on the tool. Misusing a power tool can
damage the tool and can be very dangerous. Only accessories and attachments specifically
manufactured for use with the tool should be used.

Don’t skimp on expendables

Portable electric power tools are only as good as the bits, blades, or dies that actually do the
work. These items are expensive to purchase but not nearly as expensive as the lost
productivity caused by worn bits, blades, and dies or the wear and tear they cause to portable
electric power tools. Doing the same job with worn bits, blades, and dies often takes longer,
requires the tools to work harder, and results in a lower-quality installation. In addition to being
harder on the tool, worn bits, blades, and dies also require more effort from field personnel to
get the job done, which impacts productivity and morale.

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To avoid unnecessary wear and tear on portable power tools and installer fatigue, don’t skimp
on accessories. First, make sure the field has the right sizes and types of bits, blades, and dies
to do the work. Not having the proper items will require field personnel to do the best they can
with what they have to get the job done. Again, this can result in damage to tools, and lost
productivity, low morale, and possible injury.

In addition to having the correct expendables, sufficient quantities of these items must be
available so they can be changed out when needed. There is no doubt that these items are
expensive and should be sharpened or otherwise recycled whenever possible. However, it is
false economy to believe the wear and tear on power tools and lost productivity arising from
cheap or worn bits, blades, or dies, is cheaper than replacing them when needed.

Battery packs for portable electric power tools should also be considered expendable. Batteries
also grow weak and wear out over time and need to be replaced. Sufficient battery packs and
chargers should be kept onsite to ensure field personnel will never be waiting for a battery to
charge. Also, if the work requires installers to repeatedly change bits, blades, or dies, consider
providing multiple portable electric power tools to avoid repeated change outs, which contributes
to tool wear and tear and installer fatigue.

Inspect before using:

It should be standard operating procedure for field personnel to perform visual inspection of
portable electric power tools before using them. Taking a moment to visually inspect the tool
can reveal problems that could result in a safety hazard or serious damage if not corrected
before use.
Some of the things that should be looked for on visual inspection include:
 Cracked or otherwise damaged casings and enclosures
 Broken or damaged chucks or attachment mechanisms for bits, blades, or dies
 Missing, damaged, tampered-with, or improperly operating safety guards, shields, or
other safety features
 Properly operating on-off switches
 Excessive dirt, grease, or other buildup on any part of the portable electric power tool,
including ventilation openings
 Cut, frayed, spliced, or otherwise damaged power cords
 Cracked or damaged attachment plugs, including missing or deformed grounding pins

If these or any other problems are noted during the visual inspection, the tool should be tagged
“Do Not Use.” The tool should then be returned to the shop for repair or replacement. Tags
should not be removed until repaired and tested. If a portable electric power tool is going to be
disposed of, it should have its power cord completely removed and be disposed of with the
warning tag attached so that anyone finding the tool later will know that it is damaged and
should not be salvaged or used.

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Problems during use:

If a problem is discovered when operating a portable electric power tool, cease work with that
tool immediately and fix the problem or replace the tool before proceeding. For example, if a
person using a portable power tool experiences a shock or even a tingle, that tool should
immediately be tagged “Do Not Use” until it has been fully tested and has had any problem
corrected. Removing a tool from service can prevent further damage and safety hazards.

When and how should you inspect powered hand tools?

 Inspect tools for any damage prior to each use.

 Check the handle and body casing of the tool for cracks or other damage.
 If the tool has auxiliary or double handles, check to see that they installed securely.
 Inspect cords for defects: check the power cord for cracking, fraying, and other signs of
wear or faults in the cord insulation.
 Check for damaged switches and ones with faulty trigger locks.
 Inspect the plug for cracks and for missing, loose or faulty prongs.

When portable electric power tools are returned to the shop after being used on a project, they
should be thoroughly inspected, cleaned, and tested prior to being sent back out to the field. If
calibration is required, the tool should be calibrated in accordance with manufacturer
recommendations and a calibration stamp should be placed on the tool that notes not only that
the calibration was done, but also when the next calibration should be performed if that is
appropriate. Tools carried on service trucks in continuous use should also be scheduled for
periodic inspection, cleaning, and testing.

Extension cords

Portable power tools and equipment on construction sites are needed where the work is being
performed, which may be some distance from the nearest outlet. Therefore, extension cords
must be used when battery-powered tools are not available or practical. Extension cords should
be inspected prior to use to ensure that they are in good condition.

To avoid excessive voltage drop on extension cords that can have adverse effects on tool
performance and result in damage to the tool, extension cord lengths should be kept to a
minimum and an adequate conductor size used. The conductor size is based on a current
equivalent to 150 percent of tool full-load and a maximum 5-volt voltage drop.

POWER TOOL PRECAUTIONS

Power tools can be hazardous when improperly used. There are several types of power tools,
based on the power source they use: electric, pneumatic, liquid fuel, hydraulic, and powder-
actuated.
Employees should be trained in the use of all tools not just power tools. They should understand
the potential hazards as well as the safety precautions to prevent those hazards from occurring.

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The following general precautions should be observed by power tool users:
 Never carry a tool by the cord or hose.
 Never yank the cord or the hose to disconnect it from the receptacle.
 Keep cords and hoses away from heat, oil, and sharp edges.
 Disconnect tools when not in use, before servicing, and when changing accessories
such as blades, bits and cutters.
 All observers should be kept at a safe distance away from the work area.
 Secure work with clamps or a vise, freeing both hands to operate the tool.
 Avoid accidental starting. The worker should not hold a finger on the switch button while
carrying a plugged-in tool.
 Tools should be maintained with care. They should be kept sharp and clean for the best
performance. Follow instructions in the user's manual for lubricating and changing
accessories.
 Be sure to keep good footing and maintain good balance.
 The proper apparel should be worn. Loose clothing, ties, or jewelry can become caught
in moving parts.
 All portable electric tools that are damaged shall be removed from use and tagged "Do
Not Use."

Hardening and tempering:

Certain kinds of steel, used for machine tools, can be hardened by first heating and then dipping
into water. The common types of straight carbon or low alloyed steels which are intended for
water quenching are usually heated to about 1450oF and then plunged directly into water or
brine, agitated to aid. in the cooling process. If the entire piece of metal is to be hardened, it is
important that the heating be uniform and thorough in order to accomplish this result. In the
case of hand tools, it is a common practice to heat only that portion of the tool which is to be
hard, or sometimes to heat the whole piece but dip in the water only that portion which must be
hard. If such a differential hardening is done, it is important that the design be such that no weak
section is located in that portion which would be only partially hardened. It is generally
preferable to make a difference in hardness of any part by tempering or drawing the portion
desired soft to a much higher temperature than the hard part. The tempering operation is very
important and must be performed on every piece which is hardened. Tempering should be done
just as soon as the quenched part is cool enough to be comfortably handled in the bare hands.
Tempering temperatures may vary from 225oF. to as high as 800oF., but the usual temperature
is 400-800oF. These temperatures can be judged by color, but modern practice definitely favors
use of ovens or furnaces with accurate control of the temperature. The time of tempering is
usually not less than 2 hours. An indication of the relation of heat colors to temperature is given
in the tables.

As an example of hand tempering, take the case of a cold chisel. The essential operation is to
heat it to a bright red, about 1 ½ inches from the point, then dip the point of the chisel in water.
This must be just dipped, and moved up and down slightly to avoid a sharp line of demarcation

Page 13
between the hard and soft, which may, if it occurs, causes the hard end to shear off bodily then
the chisel is put to use. As soon as the actual edge is quenched to cold, move the chisel rapidly
to the anvil, lay the hard end across the edge to support it, and rub both sides with a stone. This
brightens it sufficiently for the operator to see the temper colors as they appear, coming up in
straight lines across the shank.

Laying the edge of the chisel across the sharp edge of a cold anvil acts as a check to the
tempering, because the heat that would be conducted to the cool end is absorbed by the anvil.
As soon, therefore, as the edges are brightened. and. one can see what is happening, lift the
job from the anvil so as to allow the conducted heat from the shank to have full play. When the
right temper color reaches the actual edge, dip and, quench the whole tool. As another
example, one can consider the common twist drill, which is a more complex tool than a chisel or
ordinary turning tool. A drill is subject to considerable stress, particularly when breaking through
the underside of a surface. This is due to the fact that it has then lost the support provided by
the point. Twist drills must be hardened along the whole length of their flutes, as they untwist if
part is left soft.

Double insulated hand tools

Double insulation requires that the devices have both basic and supplementary insulation, each
of which is sufficient to prevent electric shock. All internal electrically energized components are
totally enclosed within an insulated body that prevents any contact with "live" parts. They can be
recognised because their power plugs have two pins, or on three pin plugs the third (earth) pin
is made of plastic rather than metal. In the EU, double insulated appliances all are marked with
a symbol of two squares, one inside the other.''

Hand-held tools manufactured with non-metallic cases are called double-insulated. If approved,
they do not require grounding under the National Electrical Code. Although this design method
reduces the risk of grounding deficiencies, a shock hazard can still exist.

Such tools are often used in areas where there is considerable moisture or wetness. Although
the user is insulated from the electrical wiring components, water can still enter the tool's
housing. Ordinary water is a conductor of electricity. If water contacts the energized parts inside
the housing, it provides a path to the outside, bypassing the double insulation. When a person
holding a hand tool under these conditions contacts another conductive surface, an electric
shock occurs

If a power tool, even when double-insulated, is dropped into water, the employee should resist
the initial human response to grab for the equipment without first disconnecting the power
source.

Page 14
Centralised tool control:

Tool control is an important management resource that addresses the issue of safety,
productivity and asset management. This system can promote safety by issuing the right type of
tool, encouraging employees to return damaged or worn tools, tagging and removing from
service defective tools, and encouraging the safe use of tools.
 A central control area and effective record keeping on tool failure and other causes of
injuries help locate hazardous conditions.
 A central area also assures better control than does scattered storage.
 Tools are exposed to less damage and deterioration and are not as likely to fail or create
other hazards.
 Assures uniform inspection and maintenance of tools by a trained employee.
 Can also distribute the correct type of personal protective equipment when a tool is
issued.

Steps used in tool control:

 Planning/ organisation
 Identify all tools(Including intermittently used)
 Determine the size of the tool storage unit
 Assign tool to a specific drawer
 Develop storage unit numbering/description
 Always consider the drawer height.
 List tools by numbering drawer.
 Lay tools out –confirm drawer fit
 Reserve space for future addition and changes
 Audit missing tools and overlooked requirements
The following actions are required to ensure that hand tool purchases and inventories
are adequately controlled. These controls should include requirements for prior authorization of
tool purchases and maintenance of accurate inventory records that reflect tool receipts, issues,
and quantities on hand. Basic internal controls should include prior authorization of specific tool
purchases by an individual knowledgeable of a unit's tool needs; independent checks to ensure
that tool purchases are properly received; and accurate inventory records to reflect tool receipts,
issues, and on-hand quantities. The internal audit staffs incorporate controls over hand tools
into the periodic inspections that are performed at plant and stores.

Tool tracking system:

Either a manual or computerized tool-tracking system should be used to track the location and
status of all portable electric power tools. This tracking system should include information
describing the tool, when the tool was acquired; where it is currently being used; and its
maintenance, repair, and calibration history. This tool-tracking system should be part of the
electrical contracting firm’s quality assurance program, and procedures should be documented
and put in place that address the maintenance, calibration, and testing of portable electric power
tools.

Page 15
Metal Cutting Hand Tools
Safe use of hand tools used for metal cutting:
Many types and sizes of cutters are used for cutting selected metal products made from iron,
steel, or softer, non-ferrous materials (e.g., copper, brass, aluminum). Cutters are designed to
cut materials of different kinds of products such as wires, cables (electrical, coax, multi-strand),
wire ropes, fencing, bolts, rods, pre-stressed concrete wires, and strapping.

 Wear safety glasses or goggles, or a face shield (with safety glasses or goggles) and
protective gloves when using cutters.
 Choose the proper cutter for the job. Cutters are designed for a specific type, hardness,
and size of material.
 Cut materials straight across - keep the material being cut at right angles to the cutting
edges of jaws.
 Prevent injury from flying metal by wrapping a burlap bag, cloth or rag around the cutting
jaws. Metal can fly when cut. The harder the metal, the farther it will fly.
 Warn those in the area to take precautionary measures to avoid possible injury from
flying metal pieces.
 Keep cutting tools in good repair.
 Adjust and lubricate cutter and moving parts daily if heavily used.
 Sharpen jaws according to manufacturers' instructions.

Don’ts
 Do not use a cutting tool until you are trained in its proper and safe use.
 Do not use cushion grip handles for jobs requiring insulated handles. Cushion grips are
for comfort primarily and do not protect against electric shock.
 Do not use cutters which are cracked, broken or loose.
 Do not exceed the recommended capacity of a tool.
 Do not cut diagonally.
 Do not rock cutters from side to side when cutting wire.
 Do not pry or twist with tool when cutting.
 Do not hammer on cutting tools or extend the handle length to achieve greater cutting
power.
 Do not expose cutters to excessive heat.
 Do not repair cutters. Discard equipment that is cracked, broken or shows signs of
damage.

Chisels
 Factors determining the selection of cold chisels are the materials to be cut, the size and
shape of the tool, and the depth of the cut to be made.
 The chisel should be made heavy enough so that it will not buckle or spring when struck.
 A chisel no larger than the material should be selected so that the blade is used rather
than the point or corner. Also, a hammer heavy enough to do the job should be used.

Page 16
 Employees are required to wear safety goggles when using a chisel and should set up a
shield or screen to prevent injury to other employees from flying chips. If a shield does
not give protection to all exposed employees, then all employees in the work area are
required to wear glasses with side protection.

Tap and Die Work

 Tap and die work should be firmly mounted in a vise.
 Only a T handle wrench or adjustable tap wrenchDie
should be used.
 When threads are being cut with a hand die, hands and arms should be kept clear of the
sharp threads coming through the die, and metal cuttings should be cleared away with a
brush.

Hack Saws
 Hacksaws should be adjusted in the frame to prevent buckling and breaking, but should
not be tight enough to break off the pins that support the blade.
 Install blade with teeth pointing forward.
 Pressure should be applied on the forward stroke not on the back stroke.
 If the blade is twisted or too much pressure is applied, the blade may break and cause
injury to the hands or arms of the user.

Files
 Selection of the right kind of file for the job will prevent injuries and lengthen the life of
the file.
 The file should never be cleaned by being struck against a vise or other metal object due
to file chips becoming possible flying debris.
 A file cleaning card or brush should be used.
 A file is not to be hammered or used as a pry. Use of a file in this manner frequently
results in the file chipping or breaking causing injury to the user.
 A file should not be made into a center punch, chisel, or any other type of tool because
the hardened steel may fracture in use.
Wood File
 A file is never to be used without a smooth, crack-free handle; if the file were to get hung
up, the tang may puncture the palm of the hand, the wrist, or other part of the body.
 Under some conditions, a clamp-on raised offset handle may be useful to give extra
clearance for the hands.
 Files are not to be used on lathe stock turning at high speed (faster than three turns per
file stroke) because the end of the file may strike the chuck, dog, or face plate and throw
the file (or metal chip) back at the operator hard enough to inflict serious injury.

Tin/Sheet Metal Snips

 Tin snips should be heavy enough to cut the material so easily that the employee needs
only one hand on the snips and can use the other to hold the material.
 The material is to be well supported before the last cut is made so that cut edges do not
press against the hands.
 Jaws of snips are to be kept tight and well lubricated.
Sheet Metal Snips
Page 17
  Employees are required to wear safety goggles when trimming corners or slivers of
metal because small particles often fly with considerable force.
 Employees are also required to wear gloves when making cuts.

Cutters

 Cutters used on wire, reinforcing rods, or bolts should have ample capacity for the stock;
otherwise, the jaws may be sprung or spread.
 Chips may fly from the cutting edge and injure the user.
 Frequently lubricate cutters.
 To keep cutting edges from becoming nicked or chipped, cutters are not to be used as
nail pullers or pry bars.
 Cutter jaws should have the hardness specified by the manufacturer for the particular
kind of material to be cut.
 By adjustment of the bumper stop behind the jaws, cutting edges are to be set to have a
clearance of 0.003 inch when closed.

Wood Cutting Hand Tools

Safe use of hand tools used for wood cutting:
Wood chisels are made in various shapes and sizes and for many uses. Use the correct chisel
for the job.
 Wear safety glasses, or goggles, or a face shield (with safety glasses or goggles).
 Use the right size of chisel for the job.
 Choose smooth, rectangular handles that have no sharp edges and are attached firmly
to the chisel.
 Ensure that the cutting edge is sharp. Dull chisels can be difficult to control and require
more effort to do the job.
 Check stock thoroughly for knots, staples, nails, screws or other foreign objects before
chiseling.
 Clamp stock so it cannot move.
 Adjust your stance so that you do not lose your balance if the tool slips.
 Chip or cut away from yourself.
 Keep your hands and body behind the cutting edge.
 Use a wooden or plastic mallet with a large striking face on all chisels. Only heavy-duty
or framing chisels are made of a solid or molded handle that can be struck with a steel
hammer.
 Make finishing or paring cuts with hand pressure alone.
 Place chisels safely within the plastic protective caps to cover cutting edges when not in
use.
 Replace any chisel that is bent or shows dents, cracks, chips, or excessive wear.
 Store chisels in "storage roll," a cloth or plastic bag with slots for each chisel, and keep
them in a drawer or tray.
 Replace broken or splintered handles.

Page 18
  Sharpen cutting edges as often as necessary.

Don’ts

 Do not use a wood chisel as a pry or a wedge.

 Do not use a wood chisel on metal.
 Do not use an all-steel chisel with a mushroomed face or a chipped edge. Redress with
a file or whetstone.
 Do not use a grinder to redress heat-treated tools. Use a whetstone.
 Do not use a dull chisel.

Wood Chisels
 Inexperienced employees shall be instructed in the proper method of holding and using
chisels. Handles are to be free of splinters.
 The wood handle of a chisel struck by a mallet is to be protected by a metal or leather
cap to prevent it from splitting.
 The work to be cut must be free of nails to avoid damage to the blade or cause a chip to
fly into the user's face or eye.

Saws
 Saws should be carefully selected for the work they are to do.
 For crosscut work on green wood, a coarse saw (4 to 5 points per inch) is to be used.
 A fine saw is better for smooth, accurate cutting when using dry wood.
 Saws are to be kept sharp and well set to prevent binding.
Crosscut Hand Saw
Axes

 The employee is to make sure that there is a clear circle in which to swing the axe
before chopping materials.
 All vines, brush, and shrubbery within the range should be removed, especially overhead
vines that may catch or deflect the axe.
 Axe blades are required be protected with a sheath or metal guard wherever possible.
 When the blade cannot be guarded, it is safer to carry the axe at one's side.
 The blade on a single-edged axe shall be pointed down.

Hatchets
 Hatchets shall not be used for striking hard metal surfaces since the tempered head may
injure the user or others by flying chips.
 When using a hatchet in a crowded area, employee shall take special care to prevent
injury to themselves and other employees.
 Using a hatchet to drive nails is prohibited.

Page 19
Miscellaneous Cutting Hand Tools:
Scrapers, Knives, Scalpels, Knives & Box Cutters

 Are to be used only by experienced employees. X-acto Knife

 These tools are to be kept sharp and in good condition.
 The principal hazard in the use of knives is that hands may slip from the handle onto the
blade or that the knife may strike the body or the free hand.
 A handle guard or a finger ring (and swivel) on the handle eliminates these hazards and
is required to be used.
Box Cutter
 Employees who must carry knives with them on the job shall keep them in sheaths or
holders.
 Never carry a sheathed knife on the front part of a belt, but carry it over the right or left
hip, toward the back. This will prevent severing a leg artery or vein in case of a fall.
 Knives should be stored safely and must never be left lying on benches or in other
places such as being hidden under a product, under scrap paper Pocketor wiping rags, or
Knife
among other tools in work boxes or drawers where they may cause hand injuries. Safe
placing and storing of knives is one of the most important keys to knife safety.
 Supervisors must make certain that employees who handle knives have ample room in
which to work so they are not in danger of being bumped by other employees.
 Knives are to be kept separate from other tools to protectVarious Scrapers
the cutting edge of the knife as
well as to protect the employee.
 Horseplay such as throwing knives, "fencing", trying to cut objects into smaller and
smaller pieces, and similar practices are prohibited around any knife operations.
 Supervisors shall assure that nothing is cut that requires excessive pressure on the
knife.
 Knives shall not be used as a substitute for can openers, screwdrivers, or ice picks.

Torsion Tools

Torsion tools are used to grip, fasten, and turn. These include wrenches, pliers, screwdrivers,
vises, and clamps. There are many varieties of each type of torsion tools. Selection is very
important. Here are a few safety precautions for common torsion tools:  

 Wrenches should always be pulled and not pushed. Pushing a wrench can cause a loss
of control if there is a sudden release of pressure. A short, steady pull should be used
rather than quick, jerky motions.
 Use a socket wrench instead of an adjustable or open-ended wrench. Socket wrenches
are generally easier to control, are more convenient, and are less likely to damage a bolt
or nut.
 When using an adjustable wrench, the pressure should be applied to the fixed jaw.

Page 20
  Pipe wrenches can easily slip on pipes or fittings, causing injury. To prevent slipping,
make sure that the pipe or fitting is clean and the wrench jaws are sharp and kept clean
of oil and debris.
 Pliers should never be substituted for a wrench. They do not have the same gripping
power and can easily slip on a tight object.
 When using cutting pliers, the object being cut can fly off and cause injury. Wear safety
glasses when cutting with pliers.
 Screwdrivers are often misused. They should not be used for prying, as punches, or
wedges. These misuses can damage the head of the screwdriver. A dull tip can cause
the screwdriver to slip. The tip must be flat at the tip and tapered for a snug fit on the
screw.
 When using vises, make sure that the vise is bolted to a solid base. When cutting
material in a vise, always cut as close to the vise as possible to minimize vibration. Oil
vises regularly.

Open end or Box wrenches

 Open end or box wrenches shall be inspected to make sure that they fit properly and
that the jaws are not sprung or cracked.
 When defective, the wrench is required to be taken out of service until repaired.

Socket Wrenches
 Socket wrenches are safer to use than adjustable or open-end Socket
wrenches.
 Socket wrenches give great flexibility in hard-to-reach places. The use of special types
shall be encouraged where there is danger of injury.

Adjustable Wrenches
 Adjustable wrenches are used for many purposes, but are not intended to take the place
of standard open-end, box or socket wrenches.
 They are used mainly for nuts and bolts that do not fit a standard wrench.
 Pressure is always applied to the fixed jaw.

Pipe Wrenches
 Pipe wrenches, both straight and chain tong, shall have sharp jaws and be kept clean to
prevent slipping.
 The adjusting nut of the wrench is to be inspected frequently, and taken out of service if
cracked. A cracked nut may break under strain, causing complete failure of the wrench
and possible injury to the user.
Pipe Wrench
 A piece of pipe (also called a ‘cheater’) slipped over the handle shall not be used to give
added leverage because this can strain a pipe wrench to the breaking point.
 The handle of every wrench is designed to be long enough for the maximum allowable
safe pressure.
 A pipe wrench should never be used on nuts or bolts, the corners of which will break the
teeth of the wrench, making it unsafe to use on pipe and fittings, and it also damages the
nuts/bolts.

Page 21
  A pipe wrench shall not be used on valves, struck with a hammer, nor used as a
hammer.

Pliers

 Side cutting pliers sometimes cause injuries when short ends of wires are cut.
 A guard over the cutting edge and the use of safety glasses will help prevent eye
injuries.
Slip Joint Pliers
 The handles of electricians' pliers are to be insulated. In addition, employees shall wear
the proper electrical rated gloves if they are to work on energized lines.
 Pliers shall not be used as a substitute for a wrench.

Special Cutters for Banding Wire/Strap

 Special cutters include those for cutting banding wire and strap. Claw hammers and pry
bars shall not be used to snap metal banding material.

Pipe Tongs
 Employees must neither stand nor jump on the tongs nor place extensions on the
handles to obtain more leverage. Larger tongs should be used if an employee
encounters either scenario.

Screwdrivers

 The practice of using screwdrivers for punches, wedges, pinch bars, or pry-bars shall not
be allowed.
 Cross slot (Phillips head) screwdrivers are safer than the square bit type, because they
Screwdrivers
have fewer tendencies to slip. The tip must be kept clean and sharp, however, to permit
a good grip on the head of the screw.
 The part to be worked upon must never be held in the hands; it should be laid on a
bench or flat surface or held in a vise.
 No screwdriver used for electrical work shall have the blade or rivet extending through
the handle. Both blade and handle shall be insulated except at the tip.

Shock Tools/Impact tools

Impact tools include various types of hammers like riveting hammers, carpenter's claw
hammers, and sledgehammers. The main hazard associated with all these tools is damage to
the hands and arms. The following safety procedures should be employed when using
hammers:

 The handle shall be securely fitted and suited for the type of job and type of
hammerhead. The striking face of the hammer shall be kept well dressed according to
the application.
 The handle shall be smooth and free of oil to prevent slippage.

Page 22
  Safety goggles shall be worn at all times when hammering to protect from flying nails,
wood chips, and metal or plastic fragments.
 To properly drive a nail, hold the hammer near the end of the handle and start off with a
light blow. Increase power after the nail is set.
 To avoid chipping of the hammer head, use the lightest swing possible, hammer straight
and not on an angle. Inspect the head of the hammer for potential chipping.

Hammers
 A hammer is to have a securely wedged handle suited to the type of head used. The
handle shall be smooth, without cracks or splinters, free of oil, shaped to fit the hand,
and of the specified size and length. Employees shall be warned against using a steel
hammer on hardened steel surfaces. Instead, a soft-head hammer or one with a plastic,
wood, or rawhide head should be used. Safety goggles or safety glasses shall be worn
to protect against flying chips, nails, or scale.

Riveting Hammers
 Riveting hammers, often used by sheet metal employees, must have the same kind of
use and care as ball pen hammers and should be watched closely for cracked or
chipped faces.

Carpenter's or Claw Hammers

 The faces shall be kept well dressed at all times to reduce theRiveting
hazard of flying nails while
they are being started into a piece of wood.
 A checker faced head is sometimes used to reduce this hazard.
Claw by all
**When nailing is being conducted in a work area, eye protection is advised to be used
employees nailing and all employees working in the same area. Hamme

Spark-Resistant Hand Tools

Around flammable substances, sparks produced by iron and steel hand tools can be a
dangerous ignition source. Where this hazard exists, spark-resistant tools made from brass,
plastic, aluminum, or wood will provide for safety.

Non-sparking" tool
"Non-sparking", "spark reduced", "spark-resistant" or "spark-proof" tools are names given to
tools made of metals such as brass, bronze, Monel metal (copper-nickel alloy), copper-
aluminum alloys (aluminum bronze), or copper-beryllium alloys (beryllium bronze).
Commonly used hand tools are often manufactured of steel alloys. Preferred "non-sparking"
metals have less tensile strength than steels usually used to make tools. A lower tensile
strength means the metal has less strength or resistance to tearing apart when stretched under
test conditions. It also means that these tools are softer, wear down more quickly than ordinary
steel tools, and have to be dressed more frequently.

What is the most important thing to know about "non-sparking" tools?

Page 23
Non-sparking tools also generate sparks sometimes referred to as “cold sparks”. These cold
sparks have a low heat level and do not ignite carbon disulfide, which has the lowest ignition
point of any substance known to man. Therefore while “non-sparking” tools may lower the risk of
a spark, they do not eliminate the possibility of sparks. The name "non-sparking" is misleading
because these tools are capable of producing a spark: the term "reduced-sparking tools" better
describes these tools.
Non-metals like wood, leather, and plastic are suitable for some tools like shovels, scrapers or
scoops and do not pose a friction spark hazard.
Non-sparking tools provide protection against fires and explosions in environments where there
is a concern about sparks igniting flammable solvents, vapors, liquids, dusts or residues. There
are many standards and recommendations that have been published by OSHA (Occupational
Health and Safety Administration) and NFPA (National Fire Protection Association) that advise
the use of non-sparking tools in hazardous environments.

NOTE: It is important to assess each situation carefully and use the appropriate tools for the
hazards that are present. In some cases, “non-sparking” tools may still be able to produce a
spark. Contact the tool manufacturer, and the producer of the flammable material (for example)
for recommendations and more information.

What are the hazards of both "sparking" and "non-sparking" tools?

Both "sparking" and "non-sparking" materials can cause ignition. Two types of hazards are
associated with tools manufactured of either material.
 Ignition by friction, with impact on each other or on other materials such as steel or
concrete, in which an "ordinary" (mechanical or frictional) spark is generated. All tools
can ignite flammable mixtures by sparks generated by friction or impact. However, this is
true only when the generated spark is incendive: that means a spark that has to have
enough heat content (i.e., enough mass and sufficiently high temperature) and has to
last long enough to heat a flammable air-vapour mixture above its ignition temperature.
This is more likely in the case of sparks formed when using a metal grinder that a spark
generated when a hammer strikes some metal.
 Ignition by a chemically-generated spark, caused by impact between certain metals and
some oxygen-containing substances (such as rust, which is iron oxide).

How should you use and maintain "non-sparking" tools?

 Follow the guidelines below to reduce the risk of explosion and fire.
 Make sure all "non-sparking" tools are kept clean and free from ferrous or other
contaminants, which may hamper the non-sparking properties.
 Do not use non-sparking hand tools in direct contact with acetylene, which may form
explosive acetylides, especially in the presence of moisture.
 Use local or mechanical ventilation systems as appropriate to remove hazardous
materials, dusts and vapors from the workplace.
 Follow normal safety procedures when sharpening non-sparking tools such as the
provision of eye and face protection, adequate extraction and dust collection facilities.

Page 24
What is the best safeguard against accidental explosions?
 Follow safe work procedures.
 Always evaluate a job to be done in a hazardous environment (even the simplest one)
 Use proper tools and equipment that eliminate ignition such as electric motors that can
be certified as "explosion proof" for use in most hazardous work locations or non-
sparking tools with proper use and maintenance.
 Keep in mind that there are no truly non-sparking tools.
 In any work where flames are used, or sparks are produced, make sure that an
explosive atmosphere does not develop. Such atmospheres include flammable vapour-
air mixtures and organic dust clouds like flour or coal dust. Isolation, ventilation and
purging are methods of insuring a safe working atmosphere. Use explosimeters in the
workplace to protect those working in hazardous environments.

Page 25
SAFE USE OF HAND TOOLS AND PORTABLE POWER TOOLS

1. SCREWDRIVERS
A screwdriver is the most commonly used and abused tool. The practice of using screwdrivers
as punches, wedges, pinch bars, or pry pars shall be discouraged as this practice dulls blades
and causes employee injury.
Screwdriver tips shall be selected to fit the screw. Sharp edged bits will not slip as easily as
ones that are dull. Redress tips to original shape and keep them clean.
Always hold work in a vise or lay it on a flat surface to lessen the chance of injury if the
screwdriver should slip.
When working near electrical equipment, screwdrivers shall be equipped with insulated handles
(some also come with insulated blades)

2. HAMMERS
Wooden handles shall be straight grained and free of slivers or splinters. Once split, handles
shall be replaced. Make sure handles are tightly wedged.
 Never strike a hammer with another hammer.
 Discard any hammer that shows chips, dents, etc. Redressing is not recommended.
 Safety glasses shall be worn while using a hammer or any other striking tool.
 Never use a common nail hammer to strike other metal objects such as cold chisels.

3. PUNCHES
Never use a punch with a mushroomed struck face or with a dull, chipped, or deformed point.
Punches that are bent, cracked, or chipped shall be discarded. Safety glasses shall be worn
while using a punch.

4. CHISELS
Choose a chisel only large enough for the job so the blade is used, rather than only the point or
corner. Never use chisels with dull blades–the sharper the tool, the better the performance.
Chisels that are bent, cracked, or chipped shall be discarded. Re-dress cutting edge or struck
end to original contour as needed. When chipping or shearing with a cold chisel, the tool shall
be held at an angle that permits one level of the cutting edge to be flat against the shearing
plane.

5. HACKSAWS
 Hacksaws shall be adjusted and tightened in the frame to prevent buckling and breaking,
but shall not be tight enough to break off the pins that support the blade. Install blade
with teeth pointing forward.

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  Pressure shall be applied on the forward stroke only. Lift the saw slightly, pulling back
lightly in the cut to protect the teeth. Do not bend and twist the blade. Never continue an
old cut with a new blade.

6. FILES
 Select the right file for the job, making sure that it has a secure handle.
 Files shall be cleaned only with file-cleaning cards; never by striking. Never use a file as
a pry or hammer, as chipping and breaking could result in user injury.
 Grasp the file firmly in one hand and use the thumb and forefinger of the other to guide
the point.

7. AXES AND HATCHETS

 The cutting edges are designed for cutting wood and equally soft metal. Never strike
against metal, stone, or concrete.
 Never use an axe or hatchet as a wedge or maul, never strike with the sides, and never
use them with loose or damaged handles.
 Proper axe grip for a right-handed person is to have the left hand about 3″ from the end
of the handle and the right hand about ¾ of the way up. Reverse hands if left handed.
 Sharp, well-honed axes and hatchets are much safer to use because “glancing” is
minimized.
 Safety glasses and safety shoes shall be worn and clear swinging checked before using
axes and hatchets. Axes and hatchets shall be carried with the covers on.

8. KNIVES
 Knives cause more disabling injuries than any other hand tool. The hazards are that the
hands may slip from the handle onto the blade or that the knife may strike the body or
the free hand. Use knives with handle guards if possible. Knives shall be kept sharp and
in their holders, cabinets, or sheaths when not in use; the cutting stroke shall be away
from the body.
 Do not wipe dirty or oily knives on clothing. To clean, the blade shall be wiped with a
towel or cloth with the sharp edge turned away from the wiping hand. Horseplay of any
kind (throwing, “fencing,” etc.) shall be prohibited.

9. CROWBARS
Use the proper kind and size for the job. Never use makeshifts such as pieces of pipe, as they
may slip and cause injury. Crowbars shall have a point or toe of such shape that it will grip the
object to be moved and a heel to act as a pivot or fulcrum. A block of wood under the heel may
prevent slippage and help reduce injuries.

10. SHOVELS
 Shovel edges shall be kept trimmed and handles checked for splinters and cracks.
Workers shall wear safety shoes with sturdy soles. They shall have feet well separated

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 to get good balance and spring in the knees. The leg muscle will take much of the load.
To reduce the chance of injury, the ball of the foot (not the arch) shall be used to press
the shovel into the ground or other material.
 Dipping the shovel in water or greasing or waxing the shovel will prevent some materials
from sticking.
 Gloves shall be worn while using shovels.
 When not in use, hang up shovels, stand them against the wall, or keep them in racks or
boxes.

11. BOX AND SOCKET WRENCHES

 The use of box and socket wrenches is indicated where a heavy pull is necessary and
safety is a consideration. Box and socket wrenches completely encircle the nut, bolt or
fitting and grip it at all corners as opposed to two corners gripped by an open end
wrench. They will not slip off laterally, and they eliminate the dangers of sprung jaws.
 Avoid overloading the capacity of a wrench by using a pipe extension on the handle or
strike the handle of a wrench with a hammer. Hammer abuse weakens the metal of a
wrench and causes the tool to break. Special heavy duty wrenches are available with
handles as long as 3′. Where possible, special penetrating oil shall be used to first
loosen tight nuts.

12. ELECTRIC SAWS
Electric saws shall be equipped with guards above and below the face plate. The lower guard
shall be checked frequently to be sure it operates freely and encloses the teeth completely
when not cutting. Circular saws shall not be crowded into the work. The motor shall be started
and stopped outside the work. At the beginning and end of the stroke or when the teeth are
exposed, the operator shall use extra care to keep the body out of the line-of-cut. Saws shall be
equipped with “dead man” controls or a trigger switch that shuts off the power when pressure is
released.

13. PORTABLE GRINDER
 Grinding wheels shall be guarded as completely as possible. They shall never be used
at greater than their rated speed. To do so may result in the wheel breaking apart due to
excessive centrifugal force. Guards shall be adjustable so the operator will be inclined to
make the adjustments rather than remove the guard. However, the guard shall be easily
removable to facilitate replacement of the wheel. In addition to mechanical guarding, the
operator shall wear safety glasses at all times.
 Care shall be exercised to protect the grinder from damage.
 Since part of the wheel is exposed, it is important the employee hold the wheel so it
does not touch his clothes or body.

14. AIR HOSES
 Workers shall be warned against disconnecting the air hose from the tool and using it to
clean machines or remove dust from clothing. Air used for cleaning shall not exceed 30

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 psi and workers shall wear safety glasses at all times when using air hoses. Brushing or
vacuuming equipment is recommended for removing dust from clothing.
 Air shall be shut off before attempting to disconnect the air hose from the air line. Any air
pressure inside the line shall be released before disconnecting.

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