HAND TOOLS AND POWER TOOLS

Prepared by H J PANDYA
MAIN CAUSES OF TOOL ACCIDENTS
. Minor injuries such as cuts, abrasions and contusions
occur when handling tools. More serious injuries such as
loss of eyes, severed linger or tendons and deep puncture
wounds. Also occur while handling tools. Most hand tool
accidents can be attributed to a few simple basic causes that
are,
• (a) Purchase of inferior tools which break during use.

• (b) Incorrect choice of tools.

• (c) Using worn out tools

• (d) Incorrect use of tools.

PREVENTION AND CONTROL OF TOOL ACCIDENTS.

• (a) Only lSl approved tools are to be purchased. These

tools are to be inspected by a qualified person before it is
brought on charge of tool room.
• (b) All technicians should be trained the use of the tools.
• (c) Centralized tool room should be established and only
serviceable tools should be issued.
• (d) Regular training in correct use of tools and constant
supervision is necessary to prevent wrong use of tools.
 Centralized and personal tool issue stems. In many industries
technicians are issued with a tool box containing all common
user tools’ when they are inducted .Only special tools and
consumables are issued from store. These tool boxes remain
with the technicians permanently. Personally held tool kits have
a number of disadvantages. They are,
• (a) Full range of tools is not readily available, resulting in
wrong use of tools.
• (b) Unserviceable tools do not get replaced promptly.
• (c) Loss of tools are not detected or reported till an accident
occurs.
• (d) Inventory control tools are not possible.
• Issue of tools from centralized tool store to workers daily on
loan as per the job requirements removes all the above
disadvantages. In centralized tool store system it is possible to
ensure the issues of correct and serviceable tools for the work
are issued. A clear policy regarding the purchase, supply, use,
storage and maintenance of hand tools which pays careful
attention to causes of accidents is required to prevent
accidents. Job specification should include precise and
accurate statements of tools required for each job. These
statements should form the basis for the firm’s tool
purchasing, inspection and maintenance program.
INSPECTION MAINTENANCE AND REPAIR OF
TOOLS.
• Managers of workshops and departments where hand
tools are used should be responsible for their regular
inspection and a proper system of withdrawing defective
tools for repair and scrapping. Tool room in charge
should be qualified technician. He should be able to
defects and take decisions to either repair or reject. Tools
that receive heavy wear such as chisel, wrenches,
sledges, cutters screwdrivers require regular maintenance
and repair. For repair and maintenance of tools adequate
facilities such as forge and grinders are required.
INSPECTION OF COMMON HAND TOOLS.
Points that need to be observed while inspecting,

(a) Chisel.
• 1. Mushrooming of chisel head.
• 2. Dull cutting edge.
(b) Hammers.
• 1. Head is securely fixed with handle.
• 2. Handle cracked
• 3. Hammer head split or badly worn.
(c) Files .Files are not repairable. Chipped and damaged files are rejected.
(d) Spanners. Splayed, split and loose spanners are' not repairableThese are
to be . rejected. Adjustable and monkey wrenches are to be examined for
damaged threads.
(e) Screw drivers. The screw drivers should be examined for cracked and
broken handles. Worn out bits should not be used.
REPAIR OF TOOLS
Tools are repaired in a workshop having a forge and a grinder.
• (a) Tempering of tools. Chisels, cutters, hammers and sledges are
made of steel. Their working edges are heat treated to with stand
impact without mushrooming and chipping.
• (b) Safe ending of tools. Chisels, rock drills, wedges, punches, cold
cutters and stamping die heads are safe ended by means of
hardening their impact surfaces. Special alloy tools that cannot be
heat treated are dressed.
• (c) Dressing of tools. Tool edges and heads are dressed by means
of grinding to remove damage while in use. Cutting and impact
surfaces are hardened and tempered during manufacture. They only
need to be sharpened by means emery or oil stone. Wood cutting
tools need fine edges. They are carefully ground and sharpened.
SAFE USE OF VARIOUS TYPES OF HAND TOOLS.

Screw driver.
• Screw driver is most commonly used hand tool. When
misused they can cause injuries. Broken handle, bent blade,
dull or twisted tip screw driver may slip out of the screw slot
and cause injury. Narrow tip screw driver will bend or break
under pressure. A rounded worn out tip will ride out of the
slot as pressure is applied. Thick tip will chew the slot of the
screw. Wide tip will tear the material the screw is fitted. The
condition of screw driver tip is very important. The tip should
be such that it must fit snuggly in the slot of the screw. A
Phillips screw driver is safer than flat blade because they do
not slip out easily
HAMMERS.
Hammers are made in different shapes and sizes with different
configurations and varying degree of hardness. Each hammer
has a specific purpose. The proper use hammer involves,
• (a) Always use eye protection.
• (b) Strike a hammer blow squarely. Avoid glancing blow,
over strikes or under strikes.
• (c) When striking another tool such as chisel, punch and
wedge the diameter of the striking surface of the hammer
should be more than the struck surface.
• (d) The hammer should be of suitable size and weight.
• (e) Never use a hammer to strike another hammer or a harder
surface.
• (f) Never use a hammer with a loose or loose handle.
CHISELS.

• Chisels are used for cutting, shaping and removing metal

that is softer than the cutting edge. There are various
types of chisels and their selection depends on material
to be cut, size and shape of the cut, depth of the cut to be
made and the chisel should be heavy and large enough
for the job. The Chisels should by sponge or rubber pad
forced down over the chisel to protect and cushion the
hand. When two workers are using the chisel and
hammer, the chisel should be held by tongs.
FILES.
• Selection of correct File for work will prevent injury, improve
the life of the file and increase production. lf misused files
tend to crack and fracture. Before using the file it is to be
ensured that the handles are rigidly fixed. The file should be
grasped by the handle in one hand and use the thumb and fore
finger of the other hand to guide the point. The file is pushed
forward while leaning down on it. The pressure is released
and the file is brought back to original position. The file
should have smooth and crack free handle to avoid injury
while using it on the revolving machines. When work to be
filed is placed on a lathe machine, the job should be done
with left hand, with file and hand clear of the chuck.
• Files must always be used with a handle which is firmly
held in one hand while .the point of ‘he file is guided by
the thumb and the forefinger of the other hand. Special
care must be taken while using a file on a job rotating on
a lathe machine. The file should never be with cloth or
rag that can be caught and pulled in by the chuck. Hand
and arm should be kept clear of the rotating chuck. Files
are brittle and must not be hammered or used as a lever
or struck on a hard object. Special cleaning cards are too
used for cleaning the files. .
WRENCHES.
• Injuries occur when wrenches slips off the out of
fastener, sudden freeing of fastener, wrench breaking and
fastener breaking. While loosening the fastener the
worker should position himself in such a way as not
loose balance and fall into moving machine or fall off a
platform. Always pull the wrench towards yourself.
Always use correct size and fit wrenches. Do not use
shims to make loose wrench fit. There are various types
of wrenches to suit different jobs. These are, open ended
wrenches, box and socket wrenches, monkey wrenches,
torque wrenches and pipe wrenches.
•
PLIERS.
• It is a general purpose tool. Pliers are meant for gripping
and cutting operation. Pliers used for electrical work are
provided with insulated handles. Pliers are not to be used
as wrenches. They slip when used as a wrench and injure
the fingers.
•

•
SPARK RESISTANT TOOLS.
• These tools are made from non-ferrous material. They
are made from Beryllium copper alloys. They are used
where flammable, explosive and volatile gases and
liquids are stored. These tools reduce fire hazards. They
do not completely eliminate fire hazards.
HAZARDS OF METAL WORKING TOOLS.
• Injuries occur while using hammer struck tools such as
cold chisels and punches. Eye injuries occur from flying
chips. Hand injuries can be reduced by using a holder or
by fitting a sponge rubber ring around the head of the
tool. Eyes are protected by goggles. Nearby workers are
protected by a screen.
SAW FRAME
Saw frame should be used while working a hacksaw blade.
Coarse pitch blades are to be used on soft metal and line
pitch blades are to be used to cut thin metal sheets or pipes.
The blades should be fitted teeth facing forward in the
frame. The blade must be correctly tensioned on the
hacksaw frame.
Main hazard of tin snip is cuts on the hands from sharp metal
edges. Gloves should be worn while using a tin snip. Heavy
cutters are used to cut thick wires, rods and bolts. The main
hazard is off-cut flying and hitting the worker in the eye. Eye
protection must be worn. Snips and cutters must be heavy enough
for the job. The jaws must be kept tight and well lubricated.
HAZARDS OF WOOD WORKING TOOLS

Injuries are caused by spayed wooden handles of the chisels or

by breaking of handle during use. Handles must be sound and
well fitted. End of the handle should be protected by a metal
band to avoid splaying under mallet blow. Most common injury
from wood saw is caused by the teeth touching the hand holding
the work piece. Injuries from axes, adzes and hatchets are
caused are caused by loose head flying off from the handle and
hitting someone or a chip hitting a worker or swing being
deflected by some obstacle causing the cutting edge to hit the
foot or leg. Handles of all the hatchets and axes must be
securely fixed .Workers should ensure that they have sufficient
room in all directions of swing their tools safely.
PORTABLE POWER TOOLS
Portable power tools are divided into five major groups
according to their power source. They are,
• (a) Electrical.

• (b) Pneumatic

• (c) Hydraulic.

• (d) Powder activated.

• (e) Gasoline.
Grinders, saws, drills and sanders are usually operated by electrical, pneumatic and
petrol driven sources. Compression tools are operated by hydraulic power. Powder
activated tools operate penetration, cutting and compression. Power tools present
same hazards as hand operated tools performing same function. In addition to this
they have some inherent risks. Since they are mobile they easily come into contact
with the operator. They are difficult to guard completely. The source of power
(electric, pneumatic and hydraulic) is brought close to operation, creating further
hazards. Most common injuries that occur while operating power tools are,
• (a) Burns
• (b) Cuts
• (c) Strains
• (d) Electrical shock
• (e) Eye injuries
• (f) Fires
• (g) Falls
• (h) Explosions
SAFETY PRECAUTIONS
Safety precautions that are to be observed while using power tools
are,
• (a) Always switch Off the power before changing accessories
• (b) Replace or position guards in correct place before starting the
work.
• (c) Never leave a tool at an elevated place. The electrical cord or
pneumatic hose may be accidentally pulled causing the tool to fall.
The cord or hose should be suspended from the tool balancer.
• (d) Cords and hoses should be kept well clear of passage ways to
avoid trapping hazard.
• (e) Cords and hoses must be kept away from wet, oily and hot
surfaces. Chemicals damage cords and hoses.
• (f) When using pneumatic and powder activated tools, proper PPE
should be worn by operators.
SAFE OPERATING PROCEDURES OF POWER TOOLS
Procedures that are to be followed while operating power tools
are,
• (a) Manufacturer's operating procedures must be strictly
followed.
• (b) Power tools should be stored in a secure place.

• (c) Work area should be clean and dry free from water, oil
and chemicals
• (d) The work should be clamped and secured.

• (e) Never use a partially serviceable tool.

• (f) Proper occupational clothing should be worn.

• (g) Only recommended accessories should be used.

ELECTRICAL POWER TOOLS

Electrical shock is a major hazard in portable electrical tools.

The hazard depends on the input voltage, resistance of the tool
and current flowing through it. Three different and alternate
types of protection against electrocution are available to users of
portable electrical tools. They are,
• (a) The use of an earth conductor which gives low resistance
path to the earth. This earths all parts of the tool which is held
or touched, so that in case of an insulation failure, the holder
receives at worst a mild shock.
• (b) The use of low voltage power to reduce the shock
potential.
• (c) Use of double insulation.
EARTHED ELECTRICAL TOOLS
Earthed electrical tools are operated at 230 volts AC (single
phase). The tools are earthed through a green wire. Serious
accidents can occur when the earth connection in a plug top
works itself loose and touches live lead. To overcome this
earth leakage circuit breaker (ELCB) is installed. Current
leakage may also occur due to bad insulation between the
current carrying line and the metal frame of the tool. This
may happen when the tool is operated in wet and humid
locations. To protect the operator in such situations Ground
fault circuit interrupter (GFCI) is used.
LOW VOLTAGE TOOLS

• Low voltage tools operating in the range of 110 V-50V

AC are extensively used. The voltage is safe form user.
These tools are fitted with special plug tops to
distinguish their voltage and make it impossible to plug
them into normal mains socket outlets. These tools are
supplied from step down transformers. The secondary
winding of the transformer should be earthed in the
middle so that maximum shock voltage does not exceed
more than 55 V.
DOUBLE INSULATION TOOLS

• Conventionally designed electrical tools have single layer of

functional insulation. And are metal encased. For small tools,
double insulation is provided by encasing the entire tool in a
nonconductive material that is shatter proof. The switching and
gripping a surface is also non-conductive. No metal part comes into
contact with the operator. A double insulated tool does not require
earth wire, ELCB or GFCI protection. Large capacity tools are
designed to cater for more power high torque. Also in addition to
functional insulation 3 reinforced insulation or protective insulation
is provided. This extra insulation is physically separated from
functional insulation. It is arranged in such a way that the
deteriorating influence such as temperature, dirt, wear will not
affect both insulations at the same time. Double insulated tools do
not require further protections. For safety insulation must be
checked periodically.
ELECTRIC DRILLS

Precautions that need to be followed while handling electrical drills are,

• (a) Confirm that the trigger switch is serviceable.
• (b) Check for broken insulation, frayed or damaged cable.
• (c) Ensure that the chuck is tightly secured to the spindle.
• (d) Tighten the chuck with key to secure the drill bit. Remove the key from the
chuck before starting the drill.
• (e) Grip the drill firmly by means of insulated handle.
• (f) Always hold the drill squarely.
• (g) Whenever the drill binds in the work, release the trigger immediately, unplug
the drill and then remove the drill bit from the work piece.
• (h) Never attempt to free a jammed bit by starting and stopping the drill
intermittently
• (i) Unplug the drill before changing the accessories.
• (j)Drill should not be carried by the cord.
• (k) Use appropriate PPE
ELECTRICAL SAW (CIRCULAR)
Following points are to be observed while using circular saw,

• (a) The saw must have guards above and below the face
plates.
• (b) Use saw with sharp blades. Dull blades cause binding,
stalling and kickback. They waste power, reduce life of the
motor.
• (c) Speed marked on the blade should match the no load rpm
of the motor.
• (d) Before each use, check blades carefully for alignment and
defects. Make sure that the flanges (washer) correctly
assembled on the shaft of the motor and blade is tight.
SAFE OPERATION OF THE CIRCULAR SAW
Following procedures are to be followed for safe operation
of the circular saw.
• a) Set blade depth to no more than 0.3 cm to 0.65 cm
greater than the thickness of the material cut.
• b) When starting to saw, allow the blade to reach full
speed before making contact with the work piece or
material.
• c) Blades may bind and kick back may occur during the
cut.
• d) When matting a partial cut or if power is interrupted,
immediately release the switch, and wait until the saw
comes to stop before removing.
• e) Never reach under the saw or work piece.
 KICK BACK
Kick back is a sudden reaction to a pinched blade that causes an uncontrolled
portable tool to lift up and out of the work piece towards the operator. Kickbacks
occur when misusing the tool. Following precautions are be taken to prevent
kickbacks while operating a circular saw,
• a) Keep the blade sharp. This help; it to cut its way out of pinching condition.
• b) Make sure that the blades are clean. Buildup of material on the surface of the
blade increases its thickness and increases friction. This increases chances of
kickback.
• C) Wet wood should not be cut. It produces high friction against the blade. The
wet saw dust load up and increase the chances of kickback.
• d) Release the switch immediately when the blade stalls or the saw stalls.
• e) Never use a bent, broken or warped blade. They may and result in kickback.
• f) Over heating a blade can cause it to warp and may result in kickback. Buildup
of sap on the blade, insufficient set, dullness of blades and unguided cuts can
cause overheating.
ROTARY GRINDERS
Following safety precautions are to be followed while operating
a rotary grinder,
• a) Ensure grinder switch is off before plugging in the power.
• b) Hold the grinder wheel away before starting.
• c) Remove all the flammable material away from the work
space. Sparks generated by the grinder may ignite any
flammable material.
• d) Use grinding wheel while working on hard material. Use
rotary file while for soft material.
• e) Soft materials such as Aluminum, COPPER, Brass, wood
cause excessive loads on the wheel. The wheel may crack and
break and injure the operator.
• f) Before each use check for tightness of the wheel. Loose
wheels are dangerous. Do not over tighten the collate
SANDERS
Belt and disc sanders cause serious bums, when rapidly moving abrasives touch the body. It is not possible to guard sanders
completely. Workers are to be trained in the operation of sanders. Following safety precautions are to be followed while
operating a sander.

• Motion of the sander should be away from the body.

• Keep all clothing away from moving parts.
• Wear personal protective equipment.
• Sanders need careful cleaning due to its dusty nature. It needs to be dismantled and cleaned by blowing low pressure air.
• Dust created by wood sanding is explosive and hazardous. The generation of saw dust should be minimized by adequate
ventilation.
• Before connecting ensure switch of the sander is off.
• Use abrasive belts of appropriate Width.
• Always keep face and hands clear of the moving parts.
• Never lock a sander in ON position.
• Never use excessive force on the sander. Sanders weight is adjusted for required pressure. If forced it may stall, over
heat and burn. A kick back may occur.
• Do not expose the sander to liquids damp and wet locations. Always unplug the sander and store after use.
PNEUMATIC TOOLS
Airpower grinders, drills, impact hammers and air hoses have specific hazards.
Riveting guns and hammers cause noise and vibration. Flying chips are another
hazard.
• a) Trapping and stumbling due to air hoses.
• b) Hoses when accidentally disconnected act as a whip and injure people in the
vicinity. To avoid such an accident the end of the hose should be secured to the
tool by means of a chain. '
• c) Hoses must not be used for dusting clothes and machines.
• d) To avoid excess pressure from the compressor governor should be used.
• e) Before disconnecting a hose from the air line, the air should be shut off and the
trapped pressure released.
POWDER ACTUATED TOOLS
Powder actuated tools act like a loaded gun and should be treated With the same
precaution. Only assigned, qualified operator should operate power, powder actuated
or air driven tools. Following safety procedures are to be observed,
• a) Never use powder actuated tool in an explosive or flammable atmosphere.
• b) Before using a powder actuated tool, it should be inspected for cleanliness,
operation 0" moving parts and barrel is free from obstruction.
• c) Never point the tool at any one or marry a loaded tool from one job to another
all Do not load a tool unless it is to be used immediately.
• e) Never leave a loaded tool unattended. in case of misfire, the tool is to be in
operating position for 30 seconds and a second attempt is to be made to actuate
the tool. If the tool misfires again, wait for another 30 seconds and then remove
the explosive load from the tool. Warning signs should be posted in the area of
operation.
• f) Powder actuated tools should be stored in a container.
• g) Proper PPE should be worn.
• h) Fasteners are not to be driven into very hard or brittle material. Driving into
easily penetrable material should be avoided.