AN EDUCATIONAL GUIDE FOR:

HAND TOOLS

The Ohio Bureau of Workers’ Compensation

Division of Safety & Hygiene
This booklet is one in a series the Ohio Bureau of Workers’
Compensation’s (BWC’s) Division of Safety & Hygiene publish-
es to address specific workplace safety and health concerns.

Information contained in this publication is offered as sug-

gestions to help safeguard you on the job. Each task presents
its own special issues, so these guidelines cannot possibly
cover every situation.

If an injury occurs, BWC offers quick claims service to help

you get back on the job as soon as possible or into rehabili-
tation when necessary.

For more information, please contact your nearest customer

service office or visit BWC’s Web site at <www.ohiobwc.com>.

The Ohio Bureau of Workers’ Compensation

Division of Safety & Hygiene
13430 Yarmouth Drive NW, P.O. Box 338
Pickerington, Ohio 43147-0338
1-800-OHIOBWC, press 22

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Many of today’s on-the-job injuries result from the improper
use of hand tools. Workers have lost their eyesight and had
their vision impaired, tendons severed, bones broken, and
arms, legs and fingers infected through puncture wounds, all
because of unsafe practices with hand tools or use of tools
poorly designed for the specific job.

There is no set of established codes concerning the proper use

of hand tools. Because guards are not built into hand tools
like they are on power hand tools, workers must be especially
aware of safety precautions to prevent injuries.

It is necessary for trainee instructors to stress the seriousness

of using hand tools.

The right tool is the safe tool

An accident-free shop begins when workers adhere to the rule
of using the proper tools for jobs. When used properly the
right tool is the safe tool.

Safety must be an integral part of every trade training activi-

ty. Students learn why safety is so important through clear
instructions and by performing tasks that require certain skills
and knowledge.

No matter how mechanized an industry becomes, plant oper-

ations will still depend on hand tools.

It is extremely important that workers who use hand tools are

properly trained. Do not assume workers automatically know
how to use them correctly. They must know how to use hand
tools safely and understand why certain procedures are safer
than others.

Begin with hand tool training

An ideal beginning for any safety program is basic safety
training in the use of hand tools. As a result, safety awareness
will likely reach all areas of the plant.

Trainees in skilled trades must realize why emphasis is placed

on the safe use of hand tools. They also need experience,
guidance and instruction in safe practices.

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 The safe use of hand tools
All department heads should be familiar with the talent and
skill of the workers and enforce the rules regarding safe han-
dling of hand tools. Department heads also should provide spe-
cial instruction and guidance for the worker if necessary. Such
training will increase the safety of workers who use hand tools.

There is only one safe way to use hand tools, although there
are special tools for almost every craft. Keep in mind that there
are many ergonomically designed tools available today. The fol-
lowing list consists of tools most commonly used in metal-
working and woodworking industries, which also can be the
most harmful if improperly used.

Awls
Holding an awl at a right angle to the surface of the work will
prevent injury-causing slips. To make a hole with an awl, turn
it to the right and to the left as it begins piercing the materi-
al. Never carry an awl in a pocket because the sharp point may
cause an injury.

Axes
Keep axes sharp for faster chopping and greater safety. Use only
a thin-bladed narrow ax for hard wood, and a thick-bladed wide
ax for soft wood. When an ax’s edge is dull, it is more likely to
slip off the surface, rather than cut it.

Make sure there is a clear circle in which to swing an ax. Keep

axes protected by sheaths or metal guards when not in use.
Check handles regularly for splits, looseness and re-wedging.

Bits
Store bits out of the way in a rack on the bench well. Scrapes
and cuts can easily result from a storage rack of bits not kept
in a safe place.

Chisels
In most cases, the safety of a hand tool can be determined by
the condition of its cutting and striking ends, particularly in
the case of edges and pointed tools such as cold chisels.

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A cold chisel with a mushroomed head (rounded over into
sharp, thin edges by the repeated pounding of a hammer) is
a common cause of injury to the worker. When a mushroomed
head is pounded, chips may be knocked off the damaged head
and fly into the eyes of the worker. Re-dress mushroomed
heads on all hand tools.

Grind down the damaged end and then re-form it with the use
of an abrasive wheel. In the re-dressing process, a beveled
edge will enable it to stand up under more pounding.

Cold chisels
An inadequate cold chisel will buckle or spring if the proper
size and strength are not used for the metal being cut. Hold
the chisel lightly in the hollow of the hand with palm up, sup-
ported by the thumb and first two fingers.

If the hammer glances, it will strike the soft palm rather than
the knuckles. When using larger chisels that require a fist
hold, use a cushion for hand protection.

When shearing with a cold chisel, hold the tool at an angle,

which permits one bevel of the cutting edge to ride flat
against the shearing plane. Wear safety glasses when chipping
or shearing with a cold chisel. Protect people in the immedi-
ate area with a shield or screen.

Wood chisels
Always drive a wood chisel by hand in an outward direction,
away from the body.

Before using a wood chisel, remove nails and metal (such as

corrugated fastener) from the piece of work or drive them into
the material. Otherwise, chips will fly off the imbedded metal
or off the chisel itself. Avoid any type of prying or wedging
with a chisel because it can cause the steel to snap.

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Protect the sharp edges of chisels and store them in a rack,
workbench or slotted section of a tool box. Safety hazards
result if chisels are left on shelves or bench tops where they can
roll off.

Crowbars
Use the correct size crowbar for each job. Do not use makeshift
tools (cheaters), such as pipe lengths, iron bars or extensions
for leverage. To prevent slips, place a block of wood under the
head of the crowbar.

Cutters
Use heavy duty cutters when cutting heavy wire or reinforcing
wire, bolts or strapping. It is unsafe to overload a light tool.
Apply force at a right angle to the cutting edge, not at a slant.
Never use cutters near live electrical circuits. When using cut-
ters, always wear safety glasses. Never use claw hammers, crow-
bars or other pry tools to snap metal bands; use cutters and
keep a gloved hand over the end that is likely to fly. When
using cutters on bolts or reinforcing rods, hold the portion to
be cut in one hand or cover it with a glove to keep it from fly-
ing. Never tamper with the adjustment on the cutter jaws.

Make adjustments only at the tool crib or let the manufacturer

make them. In the hands of the untrained, alterations in the
operation of cutters may result in improper clearance, which
can cause the tool to bind, crack or break its jaws. Serious
injury to the user also is possible.

Files
When using a file, have secure footing before applying pressure.
Grasp the file with one hand and guide the point of the file
with the thumb and forefinger of the other hand.

Use a vice to secure the material being filed and position the
workpiece to avoid awkward filing postures. Use an offset han-
dle if it is available. Clean files require less force. The proper
way to clean a file is with a file card; never strike it against
another piece of metal because steel particles can fly off. The
file must be used in an approved handle.

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 Hacksaws
Apply pressure on the downward stroke only. After the forward
pressure stroke, slightly lift the saw and lightly pull it back in
the cut to protect the teeth. Twisting the blade or applying too
much pressure may break the blade and result in hand or arm
injuries.

Cutting too fast with a hacksaw will heat up the blade, untem-
per it and cause it to snap. Light machine oil or lubricants pro-
tect the blade against mishaps and help the hacksaw cut more
efficiently.

Hammers
Take special care in selecting the correct type of hammer han-
dle when replacements are made; each type of hammer head
has a specific type of handle. Wedge the handle securely in the
head and make sure it is free of splinters and cracks.

Never strike hardened steel surfaces with a steel hammer. Use

a soft metal hammer or one with a plastic, wood or rawhide
head. Always wear safety glasses to protect the eyes from fly-
ing chips, nail heads or scale.

Carefully inspect sledge hammers at regular intervals for split

handles and loose or chipped heads. Selecting the right ham-
mer for the job is important. Use riveting hammers for sheet
steel, carpenter or claw hammers for driving and drawing nails,
and ball-peen hammers for metal work.

Hatchets
When working with a hatchet, strike the wood lightly with the
blade and then force the blade through by striking the wood
against a solid object. Do not strike hard metal surfaces with
the hammer end of the hatchet because the hardened head may
chip or split. To avoid injuries to others, allow a sufficient
amount of space to swing the hatchet.

Hooks
Keep hand hooks sharp to prevent slips. Shield the point of the
hook with a one-inch piece of rubber hose or carry it in a spe-
cially-designed sheath, or the point of the hook can be pressed
into a small cork as a protective shield.

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 Jacks
Check the capacity plate (usually affixed to the side of the
jack’s housing) to determine the lifting power of the jack
before it is put into service. Remove the jack handle when
moving it from job to job.

Also, check the condition of the jack’s holding fixture

before each use. Broken teeth are hazardous. Place the jack
on a level surface before applying pressure and securely
anchor the base with nailed blocks or wedges, or tie it with
ropes to prevent creeping.

Set the jack at the same angle when raising the load by
using wedges, iron plates or shims to prevent slipping. If
the jack handle is not removed after reaching the desired
elevation, it might be struck, causing the jack to be top-
pled from under the load, which can result in serious injury.

Watch for leaks in hydraulic jacks, because oil and grease

on the bottom of the under side of the jack are particular-
ly hazardous.

Wear safety shoes and keep hands free of oil and grease
when working with a jack. Use substantial blocking to sup-
port the load after it has been raised.

Knives
Use hand guards, mesh gloves or other safety equipment
when working with knives. Try to cut away from the body or
keep the body clear and wear protective clothing. Avoid
jerky motions, sudden strains or other movements that
might cause loss of balance.

Keep a knife in a sheath or holder when carrying it on the

job. Knives should never be left lying on benches or
shelves. Keep them sufficiently sharp to do the work for
which they are intended.

Planes
Store all planes in a rack designed to protect the cutting
edges from damage and workers from injuries. Always keep
the cutting edge sharp. Hold material being planed secure-
ly in a vise, clamp or other holding device.

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 Pliers
Directly apply pressure across the line of a cut when using pli-
ers. Never substitute pliers for a wrench or a hammer because
pliers chew up nuts and bolt heads and make them unsafe for
use by other workers. Also, pliers cannot grip nuts or bolts
securely, which may result in loss of balance when the work-
er exerts turning force.

Electricians should use pliers with hand-insulating grips.

Make sure these protective coverings are free of cracks, holes
or broken portions.

Securely hold the coil or length of wire in a vise when cutting

it with pliers. Hold the open end of the wire with your free
hand to prevent the cut-off end from flying.

If a vise is not available, kneel on the floor and hold the wire
with one foot. Always wear safety glasses when cutting wire.

Saws
Use slow, careful, downward strokes to help the saw cut
directly across material. Do not crowd or force a saw through
the cut because the saw may buckle or fly out. Keep the saw
sharp, properly set, and free of cracks and broken teeth.

Do not hand a saw overhead on hooks or leave it on the floor.

To prevent scrapes and cuts, do not allow it to protrude from
the end or edge of a bench.

Scraper
Only experienced workers may use scrapers. Keep scrapers
sharp and in good condition. Store them in special racks to
protect the edges and other workers.

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 Screwdrivers
When driving a screw into small objects, hold the object in
a vise, not in the hand. If performing electrical work, never
use a screwdriver with a shaft that extends all the way
through its handle.

When selecting a screwdriver, consider the tip size. It

should fit snugly in the slot of the screw to be driven. Do
not use a twisted screwdriver tip; when driving pressure is
applied on a twisted screwdriver tip, it slips and can result
in injury. Never use a screwdriver as a punch, wedge, pinch-
bar, pry or chisel.

Tin snips
Use one hand to operate the snips and the other to hold the
edges of the metal being cut. Do not lean over to cut
through the entire dimension when wider, longer stock is
being cut or when the material is likely to curl up. The work-
er next to the tin snip operation should be alerted and pro-
tected from the material that falls to the floor after the
final cut. Wear safety shoes and goggles or a face shield for
protection against the upward curl or spring of the metal as
it is cut. Never force, hammer or step on the handles of tin
snips to increase leverage. Use heavier-duty snips when
extra pressure is necessary.

On heavier materials, either reduce the thickness of the

metal (if it is in layers) or operate the snips in short, creep-
ing bites.

Wrenches
Always use the correct wrench for the job. Place the jaws on
the nut and then pull the wrench, which will force it onto
the nut. Use socket wrenches for hard-to-reach places and
to loosen and tighten nuts and other fasteners with the aid
of a ratchet apparatus. The wrenches are available in a wide
range of sizes.

Box wrenches have box openings at both ends, each a dif-

ferent size, and are used to free frozen nuts.

Open-end wrenches are made with 15-degrees, different-

sized openings at either end and are used for a variety of
purposes. Do not use an open-end wrench to free frozen
nuts. Never use a hammer on an open-end wrench or use an
extension on the handle.

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Never use a pipe wrench on nuts because the corners of
the nuts or bolts are likely to break the teeth of the pipe
wrench jaws, making the tool unsafe for future use on
pipes and fittings.

Manufacturers make every size of wrench with a maximum

capacity, so the amount of leverage obtained with the
wrench handle is the maximum application. It is an
unsafe, tool-damaging practice to add more leverage.

Hand tool storage

Periodic safety inspections of infrequently used hand tools
are necessary. Mark such tools with the company’s seal or
name, and then store them in the tool cribs of the depart-
ments where they are used or other proper places.

Set up records to cover tool repairing, replacement, check-

ing and inventory. Inspect them at specific times on a
continuous basis. Neglected tools can cause serious injury.

Provide tool bins and racks at the tool crib for each kind
of hand tool owned by the company. The person who is
responsible for the tool crib should be trained in safe and
proper tool placement.

Protection against possible accidental contact with sharp-

edged tools is important. Regularly check the condition of
the tool storage area, making sure that tools are properly
stored.

Hand tools that are not properly stored often cause trip-
ping or jabbing injuries. They can topple from an overhead
storage shelf and strike a worker.

Color-coding is a system adopted by many companies to

maintain better hand-tool control. Specific tools are color-
coded to match the color of the machine or equipment on
which they are use.

This system reduces the chance of these special tools

being carried into other departments of the plant, where
mishandling might occur.

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Never place a tool box on the end of a bench where it can be
knocked onto the worker’s feet. Also, it does not belong in an
aisleway where another person may trip. If a tool box must be
placed on a workbench, protection against its being pushed
off can be provided by using a rail.

Regularly inspect tool belts for the condition of their materi-

al, their supporting strength for the tools carried, and their
ability to protect tools from damage. Make sure the belt is
secured with the necessary pouches of sufficient depth to
hold the tools firmly. The tools, however, should protrude
enough at the top to allow the worker to get a firm grip
before removing them for use.

Wear tool belts so that the tools hang at the side, hip-high.
If the worker should fall, this provides protection against
severe back and spine injures.

Hand tool maintenance

A provision for a tool maintenance procedure is one of the
most essential factors in any hand-tool safety program.
Extensively used hand tools require careful and frequent
inspection to maintain their safe use. Immediately remove
any hand tool with a defective handle from service.

When hand tools are not properly sharpened and dressed,

injuries are often caused through inefficient cutting and
glancing off the material being worked. Straighten bent
shafts, replace broken handles, and discard tools that cannot
be repaired.

A tool’s handle is often the cause of a worker’s inefficiency

and unsafe practices. If the handle is splintered, too short,
loose-fitting or otherwise poorly affixed to the tool, the work-
er who uses it is exposed to possible injury. The worker should
know how to tighten loose handles by re-wedging the end of
the handle that sticks through the head of the tool.

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Use a file rather than an abrasive wheel when dressing the
tips of screwdrivers. The file will draw less temper from the
screwdrivers. Loss of temper in a screwdriver soon results in a
damaged tool and possible injury to the worker using it. A
hand tool that is not properly dressed and reconditioned can
be hazardous.

Set up definite procedures in the safe maintenance of hand

tools and establish wear, frequency of use and inspection
guide limits.

Inspect the tool supply room at specific times and keep an

inventory. Enforce all planned procedures and rules involving
hand tool safety to reduce injuries.

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Power-actuated tools
Powder-actuated fastening tools (PATs) are popular in the con-
struction industry when jobs call for a quick method of securing
objects to concrete and steel bases. These tools work on much
the same principle as a firearm, using a gunpowder charge to
propel a fastening pin or stud.

What are PATs?

Powder-actuated tools were developed by the military during
World War II as a means of attaching steel plates to the sides of
ships, and eventually came into use in the civilian construction
industry.

There are two types of PATs—direct-acting (high velocity) and

indirect-acting (low-velocity). In a direct-acting tool, the
expanding gases created by detonation of the gunpowder charge
work directly upon the fastener, propelling it toward the base
material. In an indirect-acting tool, the gases drive a piston,
which in turn pushes the fastener into the base material.

The gunpowder cartridges for PATs fall into categories defined by

the 12 different degrees of strength, with test velocities rang-
ing from 300 to 1,290 feet per second (fps), and are color-coded
for easier identification. Cartridges formerly had to be loaded
one shot at a time, but PATs have evolved from single-shot tools
to a multiple-shot design, with cartridges available in strips of
10 or more. Fasteners also are available in strips of 10, although
the tool must still be cocked after each shot.

Fasteners, loaded into the muzzle end of the tool, are available
in many lengths and holding capacities, each designed for use
in a specific base material (hard or soft concrete, thick or thin
steel) or a specific purpose (threaded studs for bolting fixtures
to a wall, for example).

Direct-acting PATs are still manufactured and sold, but the

lower-velocity, indirect-action tools are used much more often.
In fact, the Occupational Safety and Health Administration and
the American National Standards Institute (ANSI) construction
standards recommend using “the lowest velocity tool that will
properly set the fastener.”

14
Fasteners in piston-driven tools (indirect action) travel at a
lower velocity. In addition, when the piston stops moving, the
driving action stops, reducing the chance of the fastener pen-
etrating through the base material.

While PATs operate on the same principle as a firearm and must

be handled with the same respect, there also are dissimilarities.
A PAT, for example, cannot be picked up, pointed and fired like
a gun because the tool must be pressed against a firm surface
with at least 12 pounds of pressure before the trigger will func-
tion. Other safety features include a drop-firing safety device
that prevents the firing pin from detonating the powder car-
tridge if the tool is dropped from 10 feet or lower, and a tilt
safety prevents the tool from firing if it is tilted too far from a
right angle to the surface.

Safety standards established for the construction industry

require that workers who operate PATs be thoroughly trained in
the use of the tools, and only by a certified instructor: “Only
persons trained and authorized by the tool manufacturer shall
be qualified to instruct and qualify operators for the manufac-
turer’s powder-actuated tools (ANSI A10.3).” In addition, oper-
ators must follow the manufacturer’s requirements.

Powder-actuated tools may be purchased at various hardware

stores and can be rented from tool-rental centers, but training
may not be provided. It is the responsibility of the employer to
get training for PAT users, and training must be applicable to
the tool in use, as there are different models of PATs.

PAT training should consist of: safety features of the tool,

cleaning and maintenance, and proper operation and applica-
tion. PAT operators also should be able to disassemble and re-
assemble the tool.

Before you start

A PAT operator should know the proper application of the tool,
and use it only for the intended purpose. Prior to using the
tool, it should be inspected for worn or defective parts and to
make sure the barrel is free of obstructions. A defective PAT
must not be used.

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Before fastening, the suitability of the base material must be
determined with a pre-punch test, using a hammer and fastener
to test the hardness of the material. If the point of the fastener
flattens, the material is too hard; and if the material cracks, it is
too brittle. If the fastener sinks into the material with a normal
hammer blow, the material is not hard enough. Examples of
unsuitable base materials are:
• Too hard—cast iron, welds
• Too brittle—glass, glazed tile
• Too soft-wood, drywall.

The tool’s operator must be careful when fastening into concrete

with a high quantity of hard aggregate or steel reinforcing rods.
Striking one of these can cause the fastener to fishhook and ric-
ochet toward the operator or other nearby workers.

A qualified operator should know the proper fastener to use for

each base material, and the appropriate power load must be deter-
mined. To do this, move from the weakest load to the highest,
until the proper load is found.

Recommended guidelines for base material thickness, fastener

depth, edge distances and fastener spacing must also be followed:

Concrete
• Recommended thickness—at least three times the depth of
fastener penetration;
• Fastener penetration—1 inch to 1 1/4 inch in low-strength
concrete, 3/4 inch to 1 inch in average strength concrete,
and 5/8 inch to 3/4 inch in hard concrete;
• Distance from unsupported edge—3 inches;
• Fastener spacing—2 1/2 inches apart.

Steel
• Recommended thickness—at least 3/16 inch;
• Fastener penetration—1/2 inch. For thinner steel, the point
of the fastener should penetrate the base material;
• Distance from unsupported edge—1/2 inch;
• Fastener spacing—1 inch apart.

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 Protecting yourself
Observe basic construction safety rules, such as the operators
and coworkers wearing a hard hat and eye protection, when
operating a PAT. If working in a confined space, wear hearing
protection. Never use a PAT in an explosive or flammable
atmosphere, and be careful when fastening near live electri-
cal circuits. When working on ladders or scaffolds, brace your-
self to maintain good balance. Never carry a loaded PAT from
job to job, and never point the muzzle of the PAT at any part
of your body, especially when cocking the firing mechanism.

Protecting others
For the safety of coworkers and bystanders:
• Keep the tool pointed in a safe direction;
• Do not permit bystanders in the immediate area;
• Be sure the base material has no pre-drilled holes, for a
fastener could easily pass through and injure someone;
• Do not leave the tool unattended;
• Unload the PAT when not using it, and store tools and
cartridges in a locked container;
• Maintain a safe fastening distance from the edge of
the base material because a piece could break off
and become a dangerous projectile, or the fastener
could ricochet and injure someone.

In case of misfire
In the event the PAT’s power load does not detonate immedi-
ately, follow a strict procedure to prevent accidental discharge
of the fastener. Hold the tool against the work surface for 30
seconds, giving the cartridge time to fire, then pull the trig-
ger again. If it still does not fire, eject the cartridge (holding
the tool in a downward position at all times) and inspect it
for indentation by the firing pin. If there is none, clean the
breech face of the tool to allow penetration by the firing pin.

Do not attempt to re-use the power load. Instead, dispose of

the cartridge in a pail of water.

Cleaning and maintenance

Disassemble and clean PATs each day or after each 1,000 fas-
tenings, whichever comes first, and inspect for worn or defec-
tive parts. Parts can become deformed by using too strong of
a power load with too light of a fastener, for example. Replace
the damaged parts only with parts from that tool’s manufac-
turer to ensure safe operation. Take any PAT in need of repair
out of service until the repair is made.

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For more information, call 1-800-OHIOBWC
and press 22 or access our Web site at
www.ohiobwc.com.

Better Workers’ Compensation

Built with you in mind.

Bob Taft, Governor James Conrad, Administrator/CEO

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