Hand and Portable Power Tools Program
Purpose and Objective
The company is dedicated to the protection of its employees from on-the-job injuries. This program has been adopted to ensure hand and power tools are properly used and maintained. Outlining the requirements by tool type, as in this plan, helps to simplify those requirements. The program applies to the use of all manually powered tools as well as portable powered tools.
Definitions
Constant-Pressure Switch: A switch or control that automatically shuts off power to the tool when pressure is released.
Double-Insulated Tools: Tools that provide protection against electrical shock without third-wire grounding and include an internal layer of protective insulation to isolate the housing of the tool.
Fuel-Powered Tools: Tools that are operated with gasoline or other fuels.
Hand Tools: Tools that are used manually and require no external power, such as axes and wrenches.
Hydraulic Power Tools: Tools that use liquid fluid as a power source.
Lock-On Control: A control that allows the tool operator to shut off the control in a single motion using the same finger or fingers.
Point of Operation: The area around a tool where work is performed on the material being processed.
Portable Power Tool: A portable tool that requires a source of power to operate.
Power Tools: Tools that are operated using external power such as electricity, pneumatic or hydraulic power.
Powder-Actuated Tools: Tools that operate by powder actuation, similar to the process that discharges a firearm.
Pneumatic Tools: Tools which are powered by compressed air. This includes chippers, drills, hammers and sanders.
Responsibilities
Management
Management is responsible for implementing, supporting and enforcing this program.
Supervisors are responsible for leading program implementation and ensuring that the safe work practices in this program are utilized.
Employees are responsible for:
- Reading and understanding the manufacturer’s recommendations
- Ensuring manufacturer’s recommendations are adhered to when using tools
- Inspecting tools prior to use
- Immediately tagging damaged or defective tools so they are out of service
- Understanding and following the procedures in this plan
- Never tampering with or removing safety guards
Requirements
General Safety
Hand and portable powered tools and equipment must be kept in safe condition at all times. The following practices must be in place:
- Ensure tools are in good working condition
- Tools must undergo regular maintenance
- Always use the right tool for the job
- Inspect all tools prior to use
- Keep cutting tools sharp and use a suitable cover when not in use
- Never use damaged tools
- Tag damaged tools and take out of service immediately after a defect is recognized
- Always operate tools according to manufacturer’s recommendations
- Disconnect tools when not in use
- Keep cords and hoses away from heat, sharp edges and liquids
- Never remove a guard unless conducting maintenance on the tool
- Use proper PPE:
- Safety glasses or goggles
- Face shields
- Safety toe shoes
- Hearing protection
Hazard Assessments
The company will ensure that a hazard assessment is conducted for hand and power tools when necessary. The purpose of the assessment is to identify and mitigate hazards prior to tool use. Each hazard assessment will result in recommended steps for safe tool usage. The procedure for conducting a hazard assessment is outlined below:
- Conduct a survey of each work area to identify tools or tasks that require a hazard assessment.
- Review injury and illness records to understand what tools may have caused previous injuries and ensure a hazard assessment is conducted for those identified.
- Collect and organize information, such as owner’s manuals and manufacturer’s recommendations, as well as the requirements of this program prior to the assessment.
- Determine the general job steps for tool use and record them on the form provided.
- Identify the potential hazards associated with each step.
- Identify mitigations to reduce those hazards.
- Incorporate the results of the assessment into the use of the tool and train affected employees.
Guards
The exposed moving parts of power tools must be guarded to allow for safe operation. This includes any reciprocating, rotating or other moving parts of the equipment. Guards must protect the operator and others from a variety of hazards including:
- The point of operation
- In-running nip points
- Rotating parts
- Flying chips or sparks
If a safety guard is on a tool or piece of equipment, it must not be removed while the tool is in use. Guards may be removed temporarily but only to conduct maintenance on the tool and must be replaced prior to use.
Specific requirements are in place for circular saws that have blades over 2 inches in diameter. The guard must include a retractable lower guard that protects against the teeth of the saw up until the point the saw engages in contact with the work material. The lower guard shall be capable of automatically returning to the covering position when the saw cut is completed.
Operating Controls and Switches
Some powered hand tools are required to be equipped with a switch that must have constant pressure in order to keep the power engaged. Tools with this function automatically power off when the pressure is released. These tools include:
- Drills
- Tappers
- Fastener drivers
- Angle grinders with wheels more than 2 inches in diameter (horizontal and vertical)
- Disc sanders with discs greater than 2 inches in diameter
- Belt sanders
- Reciprocating saws
- Saber saws
- Scroll saw
- Jig saws with blade shanks greater than ¼ inch wide
- Other similar tools
While a constant-pressure switch is required, these tools may also be equipped with a lock-on control which must allow employees to turn off the control in a single motion using the same fingers. The tools that must be equipped with a positive on-off switch or a lock-on switch are listed below:
- Disc sanders with discs 2 inches or less in diameter
- Grinders with wheels 2 inches or less in diameter
- Platen sanders
- Routers
- Planers
- Laminate trimmers
- Nibblers
- Shears
- Scroll saws
- Jigsaws
- Saber and scroll saws with blade shanks a nominal ¼ inch or less in diameter
Abrasive Blast Cleaning Nozzles
When using abrasive blast cleaning nozzles, equipment shall be equipped with an operating valve which is held open manually. Support valves shall be provided on which the nozzle may be mounted when not in use.
Electric Tools
Electric tools must have a grounded, three-wire cord and must be plugged into grounded receptacles. These tools must also be double insulated or powered by low voltage isolation transformers. If an adapter must be used, the adapter must be grounded. It is absolutely prohibited to remove the third prong from a plug at any time.
In order to safely operate electric tools, the following safe work practices must be followed:
- Only use tools within the specified design limitations
- Wear appropriate PPE when using electric tools
- Place cords so that they do not create a tripping hazard
- Ensure work areas have adequate lighting
- Do not use electrical tools in wet locations unless they are specifically designed for that type of use
- Store tools properly and in cool, dry locations
- Never use the power cord for hoisting or lowering tools
Always ensure that electric tools have ground-fault circuit interrupters or assured grounding.
Hand Tools
Hand tools include any tools that are used manually such as axes, chisels, hammers, pliers, saws, wrenches, etc. In order to safely use hand tools, the following guidelines must be used:
- Always use the correct tool for the job. This means hand tools may only be used for their intended purpose. For example, a screwdriver must not be used as a chisel.
- Inspect hand tools prior to use.
- Maintain hand tools in good condition.
- Always follow manufacturer’s recommendations.
- Ensure that tools with wooden handles, such hammers or axes, have tight connections and are free from splinters or cracks.
- Tag and remove damaged tools from service immediately.
- Always direct tool usage away from yourself and other employees.
- Maintain sharp blades on bladed tools such as knives and scissors. Dull tools often create greater hazards than sharp ones due to the excessive force that is used to compensate for dull blades.
- When sharp tools are not in use, cover them with an adequate sheath or holder.
- Do not use wrenches if jaws are sprung to an extent that might allow slippage to occur.
- Impact tools such as wedges and chisels must be free from mushroomed heads.
- Iron or steel tools that may produce sparks should not be used around flammable substances.
- Tools must be maintained as cleaned and free from grease.
- Always store tools properly.
- Do not carry sharp tools close to the body such as in pockets.
Hydraulic Power Tools
Tools that are hydraulically powered must be powered by fire-resistant fluids. These fluids must be capable of maintaining safe operating characteristics at high temperatures. The only exception to this is hydraulic fluids which may be used in insulated sections of aerial lifts, derrick trucks and those used on or around energized lines. Hydraulic tools must be a type which are insulating. Always use the manufacture’s recommendations for all components of the system and never exceed safe operating pressures.
Hydraulic Jacks
When using an hydraulic jack, the jack must never be used to support a lifted load. All lifted loads must be immediately blocked up once in place. Hydraulic jacks must be fitted with a stop indicator and have the manufacturer’s load limit permanently marked in an easily visible place. The load limit may never be exceeded.
When preparing a jack for use, the following should be conducted to ensure a safe set-up:
- The base must be on a firm, level surface
- The jack must be placed using a method that is correctly centered
- The jack head must be placed against a level surface
- Force must be applied evenly
Jacks must be properly maintained by regular lubrication. Each jack must be inspected according to the following:
- Jacks which are used either continuously or intermittently must be inspected every 6 months
- Jacks that are sent out of the shop must be inspected prior to leaving the shop and again upon return
- Any time a jack is subjected to a shock or abnormal load it must be inspected immediately thereafter
Liquid-Fueled Tools
Tools that are fueled with liquids, such as gasoline, will include the additional hazards of flammable or explosive vapors as well as exhaust fumes. The fuel used to power these tools must be carefully handled and stored to reduce the risk to employees.
When fueling liquid-fuel tools, the employee must first shut down and cool the engine of the tool. This reduces the likelihood of ignition of the fuel. If the tool is to be refueled within a closed area, such as a confined space, adequate ventilation must be ensured. Fire extinguishing equipment must also be available.
Pneumatic Tools
Pneumatic tools can be very dangerous due to the risk of pressurized air causing unexpected expulsion of the attachments. To reduce this risk, the tools must be inspected to ensure that they are securely fastened to the air hose prior to use with a safety clip or other retainer. Using hoses for hoisting or lowering tools is prohibited. A locking device attached to the air hose must be used to serve as a safeguard. If the hose in use is greater than ½ inch in diameter, a flow control valve must also be utilized to reduce the pressure to an acceptable level. All pneumatically driven nailers, staples and similar tools with automatic fastener feeds must not be operated at pressures of more than 100 PSI. These tools must include a safety device on the muzzle to prevent the ejecting of fasteners. If compressed air is to be used for cleanup purposes, it must be reduced to 30 PSI, and include chip guarding and appropriate PPE must be used.
An air gun must never be pointed at anyone. The hose must also be inspected for damage and maintained out of areas where it could pose a tripping hazard. Screens must also be set up to protect other individuals in the area from flying fragments when using chippers, riveting guns, staplers or air drills.
Pneumatic tools that shoot objects such as nails, staples, rivets or similar fasteners, and also operate at pressures greater 1,000 PSI, are required to be equipped with safety devices to ensure fasteners are not allowed to be ejected unless the muzzle is in contact with the work surface. Similarly, airless spray guns used for paints and fluids at pressure of 1,000 PSI or more must include manual safety devices that prevent pulling the trigger prior to the safety device release.
The following PPE must be used when employees are operating pneumatic tools:
- Safety glasses
- Safety toe shoes
- Gloves
- Hearing protection
Portable Abrasive Wheel Tools
Abrasive wheels create hazards due to the speed at which they operate. This creates the potential for fragments of materials to become projectiles. Abrasive wheel tools used for grinding, cutting, polishing and wire buffing must be equipped with guards that do the following:
- Cover the spindle end, nut and flange projections
- Maintain wheel alignment
- Do not exceed the speed of the fastenings
Prior to mounting a new wheel, the tool must be inspected for damage. The wheel must also be inspected using sound which is known as a ring test. This includes tapping the wheel lightly with a light, non-metallic instrument. The sound produced can then be interpreted to determine if the wheel contains cracks or other defects that may indicate there is a potential for breakage. When the wheel is tapped, it should ring. This indicates the wheel is stable and undamaged. If the wheel sounds flat or “dead” and does not ring, it must not be used.
Abrasive wheel cracking while in use creates a major hazard because flying projectiles may be produced. This can be prevented by ensuring the wheel fits properly on the spindle. The spindle needs to be tight enough to securely hold the wheel while not distorting the mounting flange. It should be verified that the operating speeds of the wheel and the tool are compatible and that the manufacturer’s recommendation for both are always followed.
When the tool is in operation, allow the tool to move up to operating speed before initiating grinding or cutting. When moving into place to begin work, employees must be observant of positioning and should never place themselves in the wheel’s plane of rotation. This reduces the likelihood that a wheel break would cause the employee to be hit by a projectile.
Portable grinding tools must be equipped with guards. These guards shall protect employees from the mobile wheel and flying fragments in the event of wheel breakage.
When using grinders, the following safety requirements must be practiced:
- Always use eye and/or face protection
- Always turn off power when not in use
- Do not clamp a grinder in a vise to use
Powder-Actuated Tools
Powder-actuated tools are extremely powerful and must only be used by employees who understand how to properly use these instruments. Powder-actuated tools shall be tested each day before loading to ensure they are in proper working condition. This testing must be done in accordance with the manufacturer’s recommendations. These tools must be devices that are equipped with two separate motions for firing. This prevents the tool from firing accidentally. The first motion brings the tool into a position where it may be fired. The second motion is the pulling of the trigger. The device must prevent the tool from operating unless it is against a work surface and 5 pounds of pressure are engaged.
In the event that a powder-actuated tool misfires, the operator must continue to hold the tool in the operating position for an additional 30 seconds and only then can the operator carefully remove the load in accordance with the manufacturer’s instruction. By using this method, the faulty cartridge is less likely to explode. In order to ensure an explosion does not occur, the cartridge should be placed in water immediately after removal. Powder-actuated tools that are found to be defective must be tagged and taken out of service immediately.
The following safety precautions are required when using powder-actuated tools:
- Powder-actuated tools must never be used in a flammable or explosive atmosphere
- Do not load the tool until it is ready to be used
- Do not leave a loaded tool unattended
- Unload the tool immediately after use
- Never point the tool at anyone
- Inspect the tool before use by ensuring:
- It is clean
- Moving parts can operate freely
- The barrel is free from obstructions
- Proper guarding and shielding is in place
- Attachments are appropriately manufacturer recommended
If using powder-actuated tools to apply fasteners, the following additional procedures are required:
- Fasteners must never be fired into materials that would allow the fastener to pass through to the opposite side
- Fasteners should never be driven into very hard or brittle materials that could result in chip ricochet
- Alignment guides should be used when shooting fasteners into pre-existing holes
- If high-velocity tools are used, fasteners must not be driven more than 3 inches from any unsupported edge unless a fixture or jig is used
Training Requirements
All employees must be trained in the proper use of tools prior to use. This training must include:
- Recognition of hazards associated with different types of tools
- Necessary safety precautions for each tool
- PPE required for use
- Proper use of hand-held equipment
This training must be conducted prior to any task assignment and retraining shall be conducted as necessary to maintain knowledge. Periodic training may also be necessary if the requirements of this program change or new tools are introduced to the workplace.
