Hand and Power Tools Safety: Hazards, Rules, and Precautions, Exams of Printing

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HAND and

POWER TOOLS

This informational booklet is intended to provide a generic, non-exhaustive overview of a particular standards-related topic. This publication does not itself alter or determine compliance responsibilities, which are set forth in OSHA standards themselves and the Occupational Safety and Health Act. Moreover, because interpretations and enforcement policy may change over time, for additional guidance on OSHA compliance requirements, the reader should consult current and administrative interpretations and decisions by the Occupational Safety and Health Review Commission and the courts.

Material contained in this publication is in the public domain and may be reproduced, fully or partially, without permission of the Federal Government. Source credit is requested but not required.

This information will be made available to sensory impaired individuals upon request.

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Contents iii

• What Is the Purpose of This Booklet?
• What Are the Hazards of Hand Tools?
• What Are the Dangers of Power Tools?
  • Guards...........................................................................
  • Operating Controls and Switches
  • Electric Tools
  • Portable Abrasive Wheel Tools
  • Pneumatic Tools
  • Liquid Fuel Tools
  • Powder-Actuated Tools
  • Hydraulic Power Tools
• What Help Can OSHA Provide?
  • Safety and Health Program Management Guidelines
  • State Programs............................................................
  • Consultation Services
  • Voluntary Protection Programs
  • Strategic Partnership Program....................................
  • Training and Education
  • Electronic Information
  • OSHA Publications
  • Emergencies, Complaints, and Further Assistance....
• States and Territories with Approved Plans
• OSHA Consultation Project Directory
• OSHA Area Offices
• OSHA Regional Offices

What Is the Purpose of This Booklet? 1

This booklet is designed to present to employees and employers a summary of the basic safety procedures and safeguards associated with hand and portable power tools.

Material in this booklet is based on the standards of the Occupa- tional Safety and Health Administration; this booklet, however, should not be considered as a substitute for the full safety and health standards for general industry (published in Title 29 Code of Federal Regulations (CFR), Part 1910, Subpart P), or for the construction industry (published in 29 CFR Part 1926, Subpart I). These are also available on the World Wide Web at www.osha.gov.

Employers and employees in the 26 states and territories with OSHA-approved state safety and health plans should check with their state agency. Their state may be enforcing standards and other procedures that, while “at least as effective as” federal standards, are not always identical to the federal requirements. (See page 13 for more information on state plans.)

Tools are such a common part of our lives that it is difficult to remember that they may pose hazards. Tragically, a serious inci- dent can occur before steps are taken to identify and a void or eliminate tool-related hazards.

Employees who use hand and po wer tools and are e xposed to the hazards of falling, flying, abrasive, and splashing objects, or to harmful dusts, fumes, mists, vapors, or gases must be pro vided with the appropriate personal protecti ve equipment. All electrical connections for these tools must be suitable for the type of tool and the working conditions (wet, dusty, flammable vapors). When a temporary power source is used for construction a ground-fault circuit interrupter should be used.

Employees should be trained in the proper use of all tools. Workers should be able to recognize the hazards associated with the different types of tools and the safety precautions necessary.

Five basic safety rules can help prevent hazards associated with the use of hand and power tools:

• Keep all tools in good condition with regular maintenance.
• Use the right tool for the job.
• Examine each tool for damage before use and do not use damaged tools.
• Operate tools according to the manufacturers’ instructions.

What Is the Purpose of This Booklet?

What Are the Hazards of Hand Tools? 3

Hand tools are tools that are powered manually. Hand tools include anything from axes to wrenches. The greatest hazards posed by hand tools result from misuse and improper maintenance.

Some examples include the following:

• If a chisel is used as a screwdriver, the tip of the chisel may break and fly off, hitting the user or other employees.
• If a wooden handle on a tool, such as a hammer or an axe, is loose, splintered, or cracked, the head of the tool may fly off and strike the user or other employees.
• If the jaws of a wrench are sprung, the wrench might slip.
• If impact tools such as chisels, wedges, or drift pins have mushroomed heads, the heads might shatter on impact, sending sharp fragments flying toward the user or other employees. The employer is responsible for the safe condition of tools and equipment used by employees. Employers shall not issue or permit the use of unsafe hand tools. Employees should be trained in the proper use and handling of tools and equipment.

Employees, when using saw blades, knives, or other tools, should direct the tools away from aisle areas and away from other employ- ees working in close proximity. Knives and scissors must be sharp; dull tools can cause more hazards than sharp ones. Cracked saw blades must be removed from service.

Wrenches must not be used when jaws are sprung to the point that slippage occurs. Impact tools such as drift pins, wedges, and chisels must be kept free of mushroomed heads. The wooden handles of tools must not be splintered.

Iron or steel hand tools may produce sparks that can be an ignition source around flammable substances. Where this hazard exists, spark-resistant tools made of non-ferrous materials should be used where flammable gases, highly volatile liquids, and other explosive substances are stored or used.

What Are the Hazards of Hand Tools?

4 What Are the Dangers of Power Tools?

Appropriate personal protective equipment such as safety goggles and gloves must be worn to protect against hazards that may be encountered while using hand tools.

Workplace floors shall be k ept as clean and dry as possible to prevent accidental slips with or around dangerous hand tools.

Power tools must be fitted with guards and safety switches; the y are extremely hazardous when used improperly. The types of power tools are determined by their power source: electric, pneumatic, liquid fuel, hydraulic, and powder-actuated.

To prevent hazards associated with the use of power tools, workers should observe the following general precautions:

• 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 using them, before servicing and cleaning them, and when changing accessories such as blades, bits, and cutters.
• Keep all people not involved with the work at a safe distance from the work area.
• Secure work with clamps or a vise, freeing both hands to operate the tool.
• Avoid accidental starting. Do not hold fingers on the switch button while carrying a plugged-in tool.
• Maintain tools with care; k eep them sharp and clean for best performance.
• Follow instructions in the user’ s manual for lubricating and changing accessories.
• Be sure to keep good footing and maintain good balance when operating power tools.
• Wear proper apparel for the task. Loose clothing, ties, or jewelry can become caught in moving parts.
• Remove all damaged portable electric tools from use and tag them: “Do Not Use.”

Hand and Power Tools

laminate trimmers, nibblers, shears, and scroll saws; and jigsaws, saber and scroll saws with blade shanks a nominal 1 / 4 -inch (6. millimeters) or less in diameter. It is recommended that the con- stant-pressure control switch be re garded as the preferred de vice.

Other hand-held power tools such as circular saws having a blade diameter greater than 2 inches (5.08 centimeters), chain saws, and percussion tools with no means of holding accessories securely must be equipped with a constant-pressure switch.

Electric Tools

Employees using electric tools must be aware of several dangers. Among the most serious hazards are electrical burns and shocks.

Electrical shocks, which can lead to injuries such as heart f ailure and burns, are among the major hazards associated with electric- powered tools. Under certain conditions, even a small amount of electric current can result in fibrillation of the heart and death. An electric shock also can cause the user to fall off a ladder or other elevated work surface and be injured due to the fall.

To protect the user from shock and burns, electric tools must have a three-wire cord with a ground and be plugged into a grounded receptacle, be double insulated, or be powered by a low- voltage isolation transformer. Three-wire cords contain two current- carrying conductors and a grounding conductor. Any time an adapter is used to accommodate a two-hole receptacle, the adapter wire must be attached to a known ground. The third prong must never be removed from the plug.

Double-insulated tools are a vailable that provide protection against electrical shock without third-wire grounding. On double- insulated tools, an internal layer of protecti ve insulation completely isolates the external housing of the tool.

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

• Operate electric tools within their design limitations.
• Use gloves and appropriate safety footwear when using electric tools.
• Store electric tools in a dry place when not in use.

Hand and Power Tools

• Do not use electric tools in damp or wet locations unless they are approved for that purpose.
• Keep work areas well lighted when operating electric tools.
• Ensure that cords from electric tools do not present a tripping hazard. In the construction industry, employees who use electric tools must be protected by ground-fault circuit interrupters or an assured equipment-grounding conductor program.

Portable Abrasive Wheel Tools

Portable abrasive grinding, cutting, polishing, and wire b uffing wheels create special safety problems because they may throw off flying fragments. Abrasive wheel tools must be equipped with guards that: (1) co ver the spindle end, nut, and flange projections; (2) maintain proper alignment with the wheel; and (3) do not exceed the strength of the fastenings.

Before an abrasive wheel is mounted, it must be inspected closely for damage and should be sound- or ring-tested to ensure that it is free from cracks or defects. To test, wheels should be tapped gently with a light, non-metallic instrument. If the wheels sound cracked or dead, they must not be used because they could fly apart in operation. A stable and undamaged wheel, when tapped, will give a clear metallic tone or “ring. ”

To prevent an abrasive wheel from cracking, it must fit freely on the spindle. The spindle nut must be tightened enough to hold the wheel in place without distorting the flange. Always follow the manufacturer’s recommendations. Take care to ensure that the spindle speed of the machine will not exceed the maximum operat- ing speed marked on the wheel.

An abrasive wheel may disintegrate or explode during start-up. Allow the tool to come up to operating speed prior to grinding or cuttin g. The employee should never stand in the plane of rotation of the wheel as it accelerates to full operating speed_._ 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 wheel breakage.

What Are the Dangers of Power Tools?

Eye protection is required, and head and f ace protection is recommended for employees w orking with pneumatic tools.

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

Compressed air guns should ne ver be pointed toward anyone. Workers should never “dead-end” them against themselves or anyone else. A chip guard must be used when compressed air is used for cleaning.

Use of heavy jackhammers can cause fatigue and strains. Heavy rubber grips reduce these effects by providing a secure handhold. Workers operating a jackhammer must wear safety glasses and safety shoes that protect them against injury if the jackhammer slips or falls. A face shield also should be used.

Noise is another hazard associated with pneumatic tools. Work- ing with noisy tools such as jackhammers requires proper, effective use of appropriate hearing protection.

Liquid Fuel Tools

Fuel-powered tools are usually operated with gasoline. The most serious hazard associated with the use of fuel-powered tools comes from fuel vapors that can burn or explode and also give off danger- ous exhaust fumes. The worker must be careful to handle, trans- port, and store gas or fuel only in appro ved flammable liquid containers, according to proper procedures for flammable liquids.

Before refilling a fuel-powered tool tank, the user must shut down the engine and allow it to cool to prevent accidental ignition of hazardous vapors. When a fuel-powered tool is used inside a closed area, effective ventilation and/or proper respirators such as atmosphere-supplying respirators must be utilized to a void breath- ing carbon monoxide. Fire extinguishers must also be available in the area.

Powder-Actuated Tools

Powder-actuated tools operate like a loaded gun and must be treated with extreme caution. In f act, they are so dangerous that they must be operated only by specially trained employees.

What Are the Dangers of Power Tools?

When using powder-actuated tools, an employee must wear suitable ear, eye, and face protection. The user must select a powder level—high or low velocity—that is appropriate for the powder-actuated tool and necessary to do the work without exces- sive force.

The muzzle end of the tool must have a protective shield or guard centered perpendicular to and concentric with the barrel to confine any fragments or particles that are projected when the tool is fired. A tool containing a high-velocity load must be designed not to fire unless it has this kind of safety device.

To prevent the tool from firing accidentally, two separate motions are required for firing. The first motion is to bring the tool into the firing position, and the second motion is to pull the trigger. The tool must not be able to operate until it is pressed against the w ork surface with a force of at least 5 pounds (2.2 kg) greater than the total weight of the tool.

If a powder-actuated tool misfires, the user must hold the tool in the operating position for at least 30 seconds before trying to f ire it again. If it still will not fire, the user must hold the tool in the operating position for another 30 seconds and then carefully remo ve the load in accordance with the manufacturer’s instructions. This procedure will make the faulty cartridge less likely to explode. The bad cartridge should then be put in water immediately after re- moval. If the tool develops a defect during use, it should be tagged and must be taken out of service immediately until it is properly repaired.

Safety precautions that must be follo wed when using powder- actuated tools include the following:

• Do not use a tool in an explosive or flammable atmosphere.
• Inspect the tool before using it to determine that it is clean, that all moving parts operate freely, and that the barrel is free from obstructions and has the proper shield, guard, and attachments recommended by the manufacturer.
• Do not load the tool unless it is to be used immediately.
• Do not leave a loaded tool unattended, especially where it would be available to unauthorized persons.
• Keep hands clear of the barrel end.
• Never point the tool at anyone.

Hand and Power Tools

To set up a jack, mak e certain of the follo wing:

• The base of the jack rests on a firm, level surface;
• The jack is correctly centered;
• The jack head bears against a level surface; and
• The lift force is applied evenly. Proper maintenance of jacks is essential for safety. All jacks must be lubricated regularly. In addition, each jack must be in- spected according to the following schedule: (1) for jacks used continuously or intermittently at one site—inspected at least once every 6 months, (2) for jacks sent out of the shop for special work— inspected when sent out and inspected when returned, and (3) for jacks subjected to abnormal loads or shock—inspected before use and immediately thereafter.

Hand and Power Tools

What Help Can OSHA Provide? 13

OSHA can provide extensive help through a v ariety of programs, including assistance about safety and health programs, state plans, workplace consultations, voluntary protection programs, strate gic partnerships, training and education, and more.

Safety and Health Program Management Guidelines

Working in a safe and healthful environment can stimulate innovation and creativity and result in increased performance and higher productivity.

To assist employers and employees in developing effective safety and health management systems, OSHA published recommended Safety and Health Program Management Guidelines (Federal Register 54(16): 3904-3916, January 26, 1989). These voluntary guidelines can be applied to all places of employment covered by OSHA.

The guidelines identify four general elements that are critical to the development of a successful safety and health management system. These are the following:

• Management leadership and employee involvement,
• Worksite analysis,
• Hazard prevention and control, and
• Safety and health training. The guidelines recommend specific actions, under each of these general elements, to achieve an effective safety and health manage- ment system. The Federal Register notice is available online at www.osha.gov.

State Programs

The Occupational Safety and Health Act of 1970 (OSH Act) encourages states to develop and operate their o wn job safety and health plans. OSHA approves and monitors these plans. There are currently 26 state plans: 23 cover both private and public (state and local government) employment; 3 states, Connecticut, New Jersey, and New York, cover the public sector only. States and territories with their own OSHA-approved occupational safety and health plans

What Help Can OSHA Provide?

Voluntary Protection Programs (VPP)

Voluntary Protection Programs and onsite consultation services, when coupled with an ef fective enforcement program, expand worker protection to help meet the goals of the OSH Act. The three levels of VPP—Star, Merit, and Demonstration—are designed to recognize outstanding achievements by companies that have devel- oped and implemented ef fective safety and health management systems. The VPPs motivate others to achieve excellent safety and health results in the same outstanding way as they establish a cooperative relationship between employers, employees, and OSHA.

For additional information on VPPs and how to apply, contact the OSHA regional offices listed at the end of this publication.

Strategic Partnership Program

OSHA’s Strategic Partnership Program, the newest member of OSHA’s cooperative programs, helps encourage, assist, and recog- nize the efforts of partners to eliminate serious workplace hazards and achieve a high level of worker safety and health. Whereas OSHA’s Consultation Program and VPP entail one-on-one relation- ships between OSHA and indi vidual worksites, most strategic partnerships seek to have a broader impact by building cooperative relationships with groups of employers and employees. These partnerships are voluntary, cooperative relationships between OSHA, employers, employee representatives, and others such as trade unions, trade and professional associations, uni versities, and other government agencies.

For more information on this program, contact your nearest OSHA office, or visit OSHA’s website at www.osha.gov.

Training and Education

OSHA’s area offices offer a variety of information services, such as compliance assistance, technical advice, publications, audio visual aids, and speakers for special engagements. OSHA’s Training Institute in Des Plaines, IL, pro vides basic and advanced courses in safety and health for federal and state compliance officers, state consultants, federal agency personnel, and pri vate sector employers, employees, and their representatives.

What Help Can OSHA Provide?

The OSHA Training Institute also has established OSHA Training Institute Education Centers to address the increased demand for its courses from the private sector and from other federal agencies. These centers are nonprofit colleges, universities, and other organizations that have been selected after a competition for participation in the program.

OSHA awards grants through its Susan Harwood Training Grant Program to nonprofit organizations to provide safety and health training and education to employers and w orkers in the workplace. The grants focus on programs that will educate workers and employ- ers in small business (fewer than 250 employees), training workers and employers about new OSHA standards or about high-risk activi- ties or hazards. Grants are awarded for 1 year and may be rene wed for an additional 12-month period depending on whether the grantee has performed satisfactorily.

OSHA expects each organization awarded a grant to develop a training and/or education program that addresses a safety and health topic named by OSHA, recruit workers and employers for the train- ing, and conduct the training. Grantees are also expected to follow up with people who ha ve been trained to f ind out what changes were made to reduce the hazards in their workplaces as a result of the training.

Each year OSHA has a national competition that is announced in the Federal Register and on the Internet at www.osha-slc.gov/Train- ing/sharwood/sharwood.html. For more information on grants, training, and education, contact the OSHA Training Institute, Office of Training and Education, 1555 Times Drive, Des Plaines, IL 60018; call (847) 297-4810, or see Outreach on OSHA’s website at www.osha.gov.

Electronic Information

OSHA has a variety of materials and tools available on its website at www.osha.gov. These include e-Tools, Expert Advisors, Electronic Compliance Assistance Tools (e-CATs), Technical Links, regulations, directives, publications, videos, and other information for employers and employees. OSHA’s software programs and compliance assis- tance tools “walk” you through challenging safety and health issues and common problems to f ind the best solutions for your workplace.

Hand and Power Tools