Chapter 8. Hand and Power Tools and Equipment

I. Tools can seriously injure or kill the user if not properly maintained or used. Workers must learn to recognize the hazards associated with the different types of tools and safety precautions necessary to prevent those hazards.

II. Workers using hand and power tools should follow these general safety rules.

A. Use the right tool for the right job.

B. Examine power tools for faulty parts before use.

1. Do not use tools with frayed cords or loose or broken switches.

2. Have ground prongs in place or use tools marked "double insulated".

C. Keep all tools in good condition with regular maintenance.

D. Know the application, limitation, and potential hazards of the tool used.

E. Operate according to the manufacturer's instructions.

F. Provide and use the right protective equipment.

G. Keep guards in place, in working order, and properly adjusted.

H. Maintain working areas free of clutter.

I. Keep alert of potential hazards in the working environment such as damp locations or the presence of highly combustible materials.

III. Hand tools.

A. Hand tools are nonpowered. They include anything from axes to wrenches. The greatest hazards posed by hand tools result from misuse and improper maintenance.

B. The supervisor is responsible for the safe condition of tools and equipment used by his workers, but the workers have the responsibility of using and maintaining tools properly.

C. Supervisors should caution workers that saw blades, knives, or other tools be directed away from aisle areas and other workers working in close proximity. Knives and scissors must be sharp. Dull tools can be more hazardous than sharp ones.

D. When workers are working with hand knives, boning knives, draw knives, and scissors, they should use appropriate personal protective equipment such as wire mesh gloves, wrist guards, arm guards, and aprons or belly guards.

E. Safety requires that floors be kept as clean and dry as possible to prevent accidental slips with or around dangerous hand tools.

F. Around flammable substances, sparks produced by iron or steel hand tools can be a dangerous ignition source. Where this hazard exists, sparkresistant tools made from brass, plastic, aluminum, or wood will decrease the risk.

IV. Power tool precautions.

A. 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 powderactuated.

B. Workers should be trained knowledgeable in the use and limitation of their power tools. They should understand potential hazards and safety precautions to prevent those hazards from occurring. Proper training should be provided when needed to permit safe operation of the tools.

C. The following general precautions should be observed by power tool users:

1. Never carry a tool by the cord of hose.

2. Never yank the cord or the hose to disconnect from the receptacle.

3. Keep cords and hoses away from heat, oil, and sharp edges.

4. Disconnect tools when not in use, before servicing, and when changing accessories such as blades, bits, and cutters.

5. All observers should be kept at a safe distance from the work area.

6. Secure work with clamps or a vise, freeing both hands to operate the tool.

7. Avoid accidental starting. The worker should not hold a finger on the switch button while carrying a pluggedin tool.

8. Tools should be maintained with care. They should be kept sharp and clean for the best performance. Following instructions in the user's manual for lubricating and changing accessories.

9. Be sure to keep good footing and maintain good balance.

10. The proper apparel should be worn. Loose clothing, ties, or jewelry can become caught in moving parts.

11. All portable electric tools that are damaged must be removed, or tagged "Do Not Use."

V. Guards.

A. Hazardous moving parts of a power tool need to be safeguarded. For example, belts, gears, shafts, pulleys, sprockets, spindles, drums, fly wheels, chains, or other reciprocating, rotating, or moving parts of equipment must be guarded if such parts are exposed to contact by workers.

B. Guards, as necessary, should be provided to protect the operator and others from point of operation, inrunning nip points, rotating parts, and flying chips and sparks.

C. Safety guards must never be removed when the tool is being used. For example, portable circular saws must be equipped with guards. An upper guard must cover the entire blade of the saw. A retractable lower guard must cover the teeth of the saw, except when it makes contact with the work material. The lower guard must automatically return to the covering position when the tool is withdrawn from the work.

VI. Safety switches - must be kept functional and must not be modified.

A. The following handheld powered tools must be equipped with a momentary contact "onoff" control switch: drills, tappers, fastener drivers, horizontal, vertical and angle grinders with wheels larger than two inches in diameter, disc sanders, belt sanders, reciprocating saws, saber saws, and other similar operations. These tools may also be equipped with a lockon control provided that turnoff can be accomplished by a single motion of the same finger or fingers that turn it on.

B. The following handheld powered tools may be equipped with only a positive "onoff" control switch; platen sanders, grinders with wheels two inches of less in diameter, routers, planers, laminate trimmers, nibblers, shears, scroll saws and jigsaws with blade shanks onefourth inch wide or less.

C. Other handheld powered tools such as circular saws, chain saws, and percussion tools without positive accessory holding means must be equipped with a constant pressure switch that will shut off the power when the pressure is released.

VII. Electric tools.

A. Workers using electric tools must be aware of several dangers; the most serious is the possibility of electrocution.

B. To protect the user from shock, tools must either have a three wire cord with ground or else be double insulated. Threewire cords contain two currentcarrying conductors and a grounding conductor. One end of the grounding conductor connects to the tool's metal housing. The other end is grounded through a prong on the plug. Anytime an adapter is used to accommodate a two hole receptacle, the adapter wire must be attached to a known ground. The third prong should never be removed from the plug.

C. Double insulation is more convenient. The user and the tools are protected in two ways: by normal insulation on the wires inside, and by a housing that cannot conduct electricity to the operator in the event of a malfunction.

D. The following general practices should be followed when using electric tools:

1. Electric tools should be operated within their design limitations.

2. Gloves and safety footwear are recommended during use of electric tools.

3. When not in use, tools should be stored in a dry place.

4. Electric tools should not be used in damp or wet locations.

5. Work areas should be well lighted.

VIII. Powered abrasive wheel tools.

A. Powered abrasive grinding, cutting, polishing, and wire buffing wheels create special safety problems because they may throw off flying fragments.

B. Before an abrasive wheel is mounted, it should be inspected closely and sound or ringtested to be sure that it is free from cracks or defects. To test, wheels should be tapped gently with a light nonmetallic implement. If they sound cracked or dead, they could fly apart in operation and so must not be used. A sound and undamaged wheel will give a clear metallic tone or "ring."

C. To prevent the wheel from cracking, the user should be sure it fits freely on the spindle. The spindle nut must be tightened enough to hold the wheel in place, but not tight enough to distort the flange. Follow the manufacturer's recommendations. Care must be taken to assure that the spindle speed will not exceed the abrasive wheel specifications.

D. Due to the possibility of a wheel disintegrating (exploding) during startup, the worker should never stand directly in front of the wheel as it accelerates to full operating speed.

E. Portable grinding tools need to be equipped with safety guards to protect workers, not only from the moving wheel surface, but also from flying fragments in case of breakage.

F. In addition, when using a powered grinder:

1. Always use eye protection.

2. Turn off the power when not in use.

3. Never clamp a handheld grinder in a vise.

IX. Pneumatic tools.

A. Pneumatic tools are powered by compressed air; they include chippers, drills, hammers, and sanders.

B. There are several dangers encountered in the use of pneumatic tools.

1. The main one is the danger of getting hit by one of the tool's attachments, or some kind of fastener the worker is using with the tool. Eye protection is required and face protection is recommended for workers working with pneumatic tools.

2. Noise is another hazard. Working with noisy tools such as jackhammers requires proper, effective use of ear protection. (For more information on noise, see OSHA publication 3074, Hearing Conservation.)

C. When using pneumatic tools, workers must check to see that they are fastened securely to the hose by a positive means to prevent them from becoming disconnected. A short wire or positive locking device attaching the air hose to the tool will serve as an added safeguard.

D. In general, the same precautions should be taken with an air hose that are recommended for electric cords, since the hose is subject to the same kind of damage or accidental striking and presents tripping hazards.

E. A safety clip or retainer must be installed to prevent attachments, such as chisels on a chipping hammer, from being unintentionally shot from the barrel.

F. Screens must be set up to protect nearby workers from being struck by flying fragments around chippers, riveting guns, staplers, or air drills.

G. Compressed air guns should never be pointed toward anyone. The user should never "deadend" it against him or herself or anyone else.

H. Airless spray guns which atomize paints and fluids at high pressures (1,000 pounds or more per square inch) must be equipped with automatic or visual manual safety devices which will prevent pulling the trigger until the safety device is manually released.

I. If an air hose is more than onehalf inch in diameter, a safety excess flow valve must be installed at the source of the air supply to shut off the air automatically in case the hose breaks.

J. Heavy jackhammers can cause fatigue and strains; heavy rubber grips reduce these effects by providing a secure handhold.

K. Workers operating a jackhammer must wear safety glasses and safety shoes, which protect against injury if the hammer slips or falls. A face shield should also be used.

X. Liquidfuel tools.

A. A third type of tool is fuelpowered, usually by gasoline. The most serious hazard with fuelpowered tools come from fuel vapors that can burn or explode and give off dangerous exhaust fumes.

B. The worker must be careful handling, transporting, and storing the gas or fuel in approved flammable liquid containers, according to proper procedures for flammable liquids.

C. Before the tank for a fuelpowered tool is refilled the user must shut the engine down and allow it to cool to prevent accidental igniting of hazardous vapors.

D. If a fuelpowered tool is used inside a closed area, effective ventilation and/or personal protective equipment is necessary to avoid breathing carbon monoxide. Fire extinguishers must be available in the area.

XI. Powderactuated tools.

A. Powderactuated tools operate almost like a loaded gun and should be treated with the same respect and precautions. In fact, they are so dangerous that they must be operated only by specially trained workers.

B. These tools should not be used in an explosive or flammable atmosphere.

C. Before using the tool, the worker should inspect it to determine that it is clean, that all moving parts operate freely, and the barrel is free from obstructions.

D. The tool should never be pointed at anybody.

E. The tools should not be loaded unless it is to be used immediately. A loaded tool should not be left unattended, especially where it would be available to unauthorized persons.

F. Hands should be kept clear of the barrel end.

G. To prevent the tool from firing accidentally, two separate motions are required for ignition:

1. Bring the tool into position; and

2. Pull the trigger.

H. The tools must not be able to operate until they are pressed against the work surface with a force of a least five pounds greater than the total weight of the tool.

I. If a powderactuated tool misfires, the worker should wait at least 30 seconds, then try firing it again. If it still will not fire, the user should wait another 30 seconds so that the faulty cartridge is less likely to explode, then carefully remove the load. The bad cartridge should be put in water.

J. Suitable eye and face protection are essential when using a powderactuated tool.

K. The muzzle end of the tool must have a protective shield or guard centered perpendicularly on the barrel to confine any flying fragments or particles which might otherwise create a hazard when the tool is fired. The tool must be designed so that it will not fire unless it has this kind of safety device.

L. All powderactuated tools must be designed for varying powder charges so that the user can select a powder level necessary to do the work without excessive force.

M. If the tool develops a defect during use it should be tagged and taken out of service immediately until it is properly repaired.

XII. Fasteners.

A. When using powderactuated tools to apply fasteners, there are some precautions to consider. Fasteners must not be fired into material which would let them pass through to the other side. The fastener must not be driven into materials like brick or concrete any closer than three inches to an edge of corner. In steel, the fastener must not come any closer than a halfinch from a corner or edge. Fasteners must not be driven into very hard or brittle materials which might chip or splatter, or make the fastener ricochet.

B. An alignment guide must be used when shooting a fastener into an existing hole. A fastener must not be driven into a spalled or chipped area caused by an unsatisfactory fastening.

XIII. Hydraulic power tools.

A. The fluid used in hydraulic power tools must be approved, fire resistant fluid and must retain its operating characteristics at the most extreme temperatures to which it will be exposed.

B. The manufacturer's recommended safe operating pressure for hoses, valves, pipes, filters, and other fittings must not be exceeded.

XIV. Jacks.

A. All jacks, lever and rachet jacks, screw jacks, and hydraulic jacks, must have a device which stops them from jacking up too high. Also, the manufacturer's load limit must be permanently marked in a prominent place on the jack and should not be exceeded.

B. A jack should never be used to support a lifted load. Once the load has been lifted, it must immediately be blocked up.

C. Use wooden blocking under the base if necessary to make the jack level and secure. If the lift surface is metal, place a oneinch thick hardwood block or equivalent between it and the metal jack head to reduce the danger of slippage.

D. To set up a jack be sure that:

1. the base rests on a firm level surface,

2. the jack is correctly centered,

3. the jack head bears against a level surface,

4. the lift force is applied squarely.

E. Proper maintenance of jacks is essential for safety. All jacks must be inspected before each use and lubricated regularly. If a jack is subjected to an abnormal load or shock, it should be thoroughly examined to make sure it has not been damaged.

F. Jacks exposed to freezing temperatures must be filled with an adequate antifreeze liquid.

XV. Workers and supervisors have a responsibility to work together to establish safe working procedures. If a hazardous situation is encountered, it should be brought to the attention of the proper individual immediately.