Accident Prevention Manual for Business & Industry: Engineering & Technology 13th edition National Safety Council Compiled by Dr. S.D. Allen Iske, Associate Professor University of Central Missouri

CHAPTER 20 HAND AND PORTABLE POWER TOOLS

Preventing Incidents The misuse of hand and portable power tools can cause loss of eyes and vision, puncture wounds, severed fingers, tendons, and arteries, broken bones, contusions, infections, ergonomic stress, and many other injuries. Each year hand tools are the source of 6–8 % of all compensable disabling injuries. Focus areas for preventing incidents: tool selection changing tools safety practices central tool control carrying tools

Tool Selection The tool should perform the job it is intended for. The tool must be usable by the employee and not cause discomfort or physical pain. Handle shape/form: It should minimize hand and upper body stress. It should be ergonomically well-designed to reduce hand fatigue.

Tool Selection (Cont.) Quality of the tool sharpness sturdiness reliability Vibration control Vibration may cause hand-arm syndromes; such as hand-arm vibration syndrome (HAVS), aka Reynaud’s syndrome. Provide workers with pads or gloves. Use administrative controls such as work rotation or frequent breaks. If possible, use foot controls and alternate hand and foot use.

Tool Selection (Cont.) Work stations Each work station should be adjustable so that it may be adjusted to different worker requirements. It should facilitate full range of motion. If possible, provide mechanical means of handling materials.

Tool Selection (Cont.) Work methods evaluation How much force is needed to hold and/or use the tool? What is the direction of the force? What is the weight of the materials? How many repetitions must the worker perform? What is the employee’s postural position?

Changing Tools Factors to consider when changing tools: employees’ concerns about any tool problems facility’s tool-related incident rate work methods involved workstation set-up trends for particular jobs

Safety Practices 6 safety practices that help prevent incidents involving hand and portable power tools: 1. Provide proper PPE and make sure workers use it. 2. Select the right tool for the job. 3. Make sure tools are in good condition. 4. Properly ground power tools. (CFR (b)(1)(i) GFCI- construction site requirement. 5. Use tools correctly. 6. Keep tools in a safe place.

Safety Practices (Cont.) Safety program Train employees to select the proper tool for the job. Establish regular tool inspection procedures. Train and supervise employees to correctly use tools. Establish a procedure to control company tools. check-in/check-out policy Provide proper storage areas in tool room and workstation. Enforce PPE use. Plan the job well in advance.

Central Tool Control A central tool control program assures uniform inspection and maintenance by trained employees. The tool control attendant may issue the proper PPE with the proper equipment. The program may encourage workers to turn in damaged or worn out tools. Remove from service defective tools.

Carrying Tools Tools should be carried to and from the site in an approved tool box to protect the worker(s). Sharp and/or pointed tools must be carried tip down. No tools should be in hand when climbing a ladder. Do not allow workers to leave tools overhead. Workers should pay attention to distances around them so as to avoid striking others.

Maintenance and Repair Focus areas for maintenance and repair: inspection and control redressing tools

Inspection and Control Never return a dull or damaged tool to stock. Keep a sufficient supply of high-quality tools so damaged or worn tools may be removed from service and replaced with a safe tool.

Redressing Tools Follow manufacturer’s guidance for repair, shaping or maintaining tools. Redressing should be performed by a trained professional. Specific guidelines must be followed when redressing or reshaping the following tools: hatchet flat cold chisel hot chisel machinist’s chisel punches screwdrivers files star drills

Redressing Tools (Cont.) Redressing handles Wooden handles should be made out of high-quality, straight- grained material such as hickory, ash or maple. Alternate materials of fiberglass or steel with a rubber sleeve. The handle must be securely fastened.

Use of Hand Tools The misuse of common hand tools is the source of many industrial injuries. Every training program should include a section on the proper use and maintenance of common hand tools such as screwdrivers, hammers, punches, cutting metal tools, cutting wood tools, other cutting tools, wrenches, files, material handling, spark-resistant tools, and soldering irons.

Screwdrivers Most commonly used and abused tool. Select a screwdriver tip that fits the screw. Secure materials prior to driving the screw. Use insulated screwdrivers around energized circuits. Do not use for other actions (punches, wedges, pries, etc.)

Hammers Always strike a hammer blow squarely. Properly secure material, prior to hammering. Never use a hammer to strike another hammer.

Types of Hammers Common nail hammers Ball peen hammers Sledgehammers Hand-drilling hammers Bricklayer’s hammers Riveting and setting hammers

Types of Hammers (Cont.)

Punches Punches are made to mark metal and other materials of softer material than the punch’s end, drive and remove pins and rivets, and align holes in different sections of materials. Made in various patterns from square, round, hexagonal, or octagonal steel stock. Never use punch with a poorly struck face or one that is dull, chipped, or deformed. Discard cracked, chipped, or bent punches.

Use of Hand Tools Tools for cutting metal: cold chisels/hot chisels hack saws files hand snips cutters

Use of Hand Tools (Cont.) Tools for cutting wood: wood chisel saws (use crosscut for cutting across the grain, ripping for cutting with the grain) axes (proper grip and swing execution are paramount to axe safety)

Use of Hand Tools (Cont.) Miscellaneous cutting tools: knives Keep knives sharp. Replace knives with worn blades. Use knives with retractable blades, when possible. Sheathed knives should be carried on the hips. away from major arteries/veins in case of fall Do not clean blades by wiping them across your clothing.

Use of Hand Tools (Cont.) Tools for materials handling: crowbars hooks (keep sharp with secure handles) shovels (use legs to dig, use ball of foot, not the arch) rake (never leave an unattended rake with the prongs facing upward)

Use of Hand Tools (Cont.) Wrenches Workers must be cognizant of the innate hazards of using a wrench such as: slipping sudden loosening of fastener wrench failure fastener breaking The wrench should be pulled towards the worker and should be braced properly. Do NOT modify or alter wrenches.

Use of Hand Tools (Cont.) Open-end wrench used for medium duty turning

Use of Hand Tools (Cont.) Box wrench used for heavy turning may have 6 or 12 points never use 12-point on square nut

Use of Hand Tools (Cont.) Combination wrench Use box end for initial loosening and the open end for final loosening.

Use of Hand Tools (Cont.) Torque wrench Use to tighten fasteners to manufactures specifications. Requires special maintenance procedures to maintain their calibration.

Use of Hand Tools (Cont.) Pipe wrench Specifically made to be used on tubing. Do not use “cheater bars” on pipe wrenches. Never use a pipe wrench on a nut or bolt. Do not use a pipe wrench on soft fittings.

Use of Hand Tools (Cont.) Pliers Beware of pinch points. Do not use as a substitute for a wrench.

Use of Hand Tools (Cont.) Spark resistant Use around flammable materials. Spark resistant tools only reduce spark-related hazards, they do NOT eliminate them.

Use of Hand Tools (Cont.) Soldering irons Use proper PPE (to avoid burns, inhalation, lead, etc.). Use holders that completely surround the heating element.

Portable Power Tools Power sources for portable power tools (five primary groups): electrical pneumatic gasoline hydraulic powder actuated

Hazards and Safety Precautions Power tools share many of the same hazards as hand tools; however, the power source adds additional energy output, which may lead to more serious incidents. Portability factor makes it difficult to use proper guarding. Electrical cords and air hoses present tripping hazards. Materials should be secured, prior to using power tools. Workers must use the proper PPE.

Selecting Power Tools Using power tools to replace hand tools presents additional hazards. It is important to consider the work site, use, timeframe, etc., when making your selection. Always choose a tool that is of sufficient size/capacity to perform the given job.

Inspection and Repair All power tools must be inspected and repaired on a routine basis. Inspect electrical tools as specified by the OSHA electrical safety-related work standard. Use non-flammable solvents to clean tools. Maintenance and repairs should be performed by an authorized and qualified worker.

Electrical Tools Electrical shock is one of the primary hazards. The ratio of voltage and resistance determines the amount of current that will flow and the resultant degree of hazard. Grounding and using a GFCI are effective ways to reduce the chance of shock.

Electrical Cords Inspect cords prior to use. Instruct employees not to jerk cords or wind them too tight. Cords should be protected from sharp objects, heat, and oil, or other solvents. Use the proper wire size for electrical current needs.

Electric Drills Causes of injuries: torque and twisting of the tool part of drill penetrates the worker’s body tool dropped by worker flying debris or broken drill bits eye protection

Electric Drills (Cont.) Incident prevention: Be sure the trigger switch works properly. Check for loose power-cord connections and damage to cord. Be sure the chuck is secured to the spindle. Use proper PPE (safety goggles or glasses with side shields). Hold and brace the tool securely. Do not use the cord to raise or lower the drill.

Electrical Circular Saws Guards must be in place and functioning properly. OSHA requirement: >90 volts must be grounded. Always use sharp blades. Use both hands to control the saw. Prior to cutting, the saw should reach full speed. Be aware of kickback dangers.

Reciprocating Saw It is vital that the proper blade length be used for the job. Avoid cutting above shoulder height. Do not remove the blade from the material until the blade has stopped.

Miter Saw Use proper PPE. In some cases it is not recommended to wear gloves. Never place hands in path of blade. Lock the miter head in the down position when not in use.

Jig/Saber Saws Do not plunge cut without first drilling a pilot hole. Do not remove the blade from the material until it has stopped.

Rotary Die Grinder Use proper PPE. Air sampling may be necessary. Inspect the cutting wheel prior to use.

Sanders Be aware of burn hazards. Sparks may ignite flammable materials. Be aware of dust accumulation.

Routers Only use sharp bits. Use both hands to operate the tool. Secure all materials prior to use.

Air-Powered Tools Air hose Presents a tripping or stumbling hazard. Do not allow workers to disconnect the air hose and use it to blow off their person or machine. Shut the air supply off prior to disconnecting. A small chain should be attached to the air hose next to the couplings to prevent “air hose whipping.”

Pneumatic-Impact Tools Noise is a common hazard. Use proper PPE. Require two safety devices: Automatic closing valve, activated by the trigger. Retaining device used to prevent the tool from unintentional firing from the barrel. If more than one chipper is working in the same vicinity; they should work back to back to prevent face cuts from flying chips.

Power Nailer Powered by compressed air, some are electric, others use gas fuel cartridge, or batteries. Gas fuel must be used in well-ventilated areas. Use the proper level of air pressure. Workers should not place their finger on the trigger until they are ready to fasten the material.

Specialty Tools Chain saws present unique hazards that must be mitigated: kickback vibration cutting burns from mufflers flying debris muffler ignites ground material refueling explosions

Personal Protective Equipment Employees should wear eye and face protection where flying particles present a hazard. Do not overlook eye protection on the following jobs: cutting wire or cable striking wrenches using hand drills chipping concrete shoveling material removing nails from lumber working on the leeward side of a job using wrenches and hammers overhead debris falling