The document is an accident prevention manual focusing on the safe use of hand and portable power tools in industrial settings. It outlines the potential injuries caused by tool misuse, emphasizes proper tool selection, safety practices, maintenance, and personal protective equipment, while providing guidelines for training employees. The manual includes detailed instructions for various tools and equipment, addressing risks, hazards, and necessary precautions to minimize incidents.

1. Accident Prevention Manual
for Business & Industry:
Engineering & Technology
13th edition
National Safety Council
Compiled by
Dr. S.D. Allen Iske, Associate Professor
University of Central Missouri

2. CHAPTER 20
HAND AND PORTABLE POWER TOOLS

3. Preventing Incidents
• The misuse of hand and portable power tools can cause
loss of eyes and vision, puncture wounds, severed
fingers, tendons, and arteries, broken bones, contusions,
infections, ergonomic stress, and many other injuries.
• Each year hand tools are the source of 6–8 % of all compensable
disabling injuries.
• Focus areas for preventing incidents:
• tool selection
• changing tools
• safety practices
• central tool control
• carrying tools

4. Tool Selection
• The tool should perform the job it is intended for.
• The tool must be usable by the employee and not cause
discomfort or physical pain.
• Handle shape/form:
• It should minimize hand and upper body stress.
• It should be ergonomically well-designed to reduce hand fatigue.

5. Tool Selection (Cont.)
• Quality of the tool
• sharpness
• sturdiness
• reliability
• Vibration control
• Vibration may cause hand-arm syndromes; such as hand-arm
vibration syndrome (HAVS), aka Reynaud’s syndrome.
• Provide workers with pads or gloves.
• Use administrative controls such as work rotation or frequent
breaks.
• If possible, use foot controls and alternate hand and foot use.

6. Tool Selection (Cont.)
• Work stations
• Each work station should be adjustable so that it may be adjusted
to different worker requirements.
• It should facilitate full range of motion.
• If possible, provide mechanical means of handling materials.

7. Tool Selection (Cont.)
• Work methods evaluation
• How much force is needed to hold and/or use the tool?
• What is the direction of the force?
• What is the weight of the materials?
• How many repetitions must the worker perform?
• What is the employee’s postural position?

8. Changing Tools
• Factors to consider when changing tools:
• employees’ concerns about any tool problems
• facility’s tool-related incident rate
• work methods involved
• workstation set-up
• trends for particular jobs

9. Safety Practices
• 6 safety practices that help prevent incidents involving
hand and portable power tools:
1. Provide proper PPE and make sure workers use it.
2. Select the right tool for the job.
3. Make sure tools are in good condition.
4. Properly ground power tools. (CFR 1926.404 (b)(1)(i) GFCI-
construction site requirement.
5. Use tools correctly.
6. Keep tools in a safe place.

10. Safety Practices (Cont.)
• Safety program
• Train employees to select the proper tool for the job.
• Establish regular tool inspection procedures.
• Train and supervise employees to correctly use tools.
• Establish a procedure to control company tools.
• check-in/check-out policy
• Provide proper storage areas in tool room and workstation.
• Enforce PPE use.
• Plan the job well in advance.

11. Central Tool Control
• A central tool control program assures uniform inspection
and maintenance by trained employees.
• The tool control attendant may issue the proper PPE with
the proper equipment.
• The program may encourage workers to turn in damaged
or worn out tools.
• Remove from service defective tools.

12. Carrying Tools
• Tools should be carried to and from the site in an approved
tool box to protect the worker(s).
• Sharp and/or pointed tools must be carried tip down.
• No tools should be in hand when climbing a ladder.
• Do not allow workers to leave tools overhead.
• Workers should pay attention to distances around them so
as to avoid striking others.

13. Maintenance and Repair
• Focus areas for maintenance and repair:
• inspection and control
• redressing tools

14. Inspection and Control
• Never return a dull or damaged tool to stock.
• Keep a sufficient supply of high-quality tools so damaged
or worn tools may be removed from service and replaced
with a safe tool.

15. Redressing Tools
• Follow manufacturer’s guidance for repair, shaping or
maintaining tools.
• Redressing should be performed by a trained professional.
• Specific guidelines must be followed when redressing or
reshaping the following tools:
• hatchet
• flat cold chisel
• hot chisel
• machinist’s chisel
• punches
• screwdrivers
• files
• star drills

16. Redressing Tools (Cont.)
• Redressing handles
• Wooden handles should be made out of high-quality, straight-
grained material such as hickory, ash or maple. Alternate materials
of fiberglass or steel with a rubber sleeve.
• The handle must be securely fastened.

17. Use of Hand Tools
• The misuse of common hand tools is the source of many
industrial injuries.
• Every training program should include a section on the
proper use and maintenance of common hand tools such
as screwdrivers, hammers, punches, cutting metal tools,
cutting wood tools, other cutting tools, wrenches, files,
material handling, spark-resistant tools, and soldering
irons.

18. Screwdrivers
• Most commonly used and abused tool.
• Select a screwdriver tip that fits the screw.
• Secure materials prior to driving the screw.
• Use insulated screwdrivers around energized circuits.
• Do not use for other actions (punches, wedges, pries, etc.)

19. Hammers
• Always strike a hammer blow squarely.
• Properly secure material, prior to hammering.
• Never use a hammer to strike another hammer.

20. Types of Hammers
• Common nail hammers
• Ball peen hammers
• Sledgehammers
• Hand-drilling hammers
• Bricklayer’s hammers
• Riveting and setting hammers

21. Types of Hammers (Cont.)

22. Punches
• Punches are made to mark metal and other materials of
softer material than the punch’s end, drive and remove
pins and rivets, and align holes in different sections of
materials.
• Made in various patterns from square, round, hexagonal, or
octagonal steel stock.
• Never use punch with a poorly struck face or one that is
dull, chipped, or deformed. Discard cracked, chipped, or
bent punches.

23. Use of Hand Tools
• Tools for cutting metal:
• cold chisels/hot chisels
• hack saws
• files
• hand snips
• cutters

24. Use of Hand Tools (Cont.)
• Tools for cutting wood:
• wood chisel
• saws (use crosscut for cutting across the grain, ripping for cutting
with the grain)
• axes (proper grip and swing execution are paramount to axe
safety)

25. Use of Hand Tools (Cont.)
• Miscellaneous cutting tools: knives
• Keep knives sharp.
• Replace knives with worn blades.
• Use knives with retractable blades, when possible.
• Sheathed knives should be carried on the hips.
• away from major arteries/veins in case of fall
• Do not clean blades by wiping them across your clothing.

26. Use of Hand Tools (Cont.)
• Tools for materials handling:
• crowbars
• hooks (keep sharp with secure handles)
• shovels (use legs to dig, use ball of foot, not the arch)
• rake (never leave an unattended rake with the prongs facing
upward)

27. Use of Hand Tools (Cont.)
• Wrenches
• Workers must be cognizant of the innate hazards of using a
wrench such as:
• slipping
• sudden loosening of fastener
• wrench failure
• fastener breaking
• The wrench should be pulled towards the worker and should be
braced properly.
• Do NOT modify or alter wrenches.

28. Use of Hand Tools (Cont.)
• Open-end wrench
• used for medium duty turning

29. Use of Hand Tools (Cont.)
• Box wrench
• used for heavy turning
• may have 6 or 12 points
• never use 12-point on square nut

30. Use of Hand Tools (Cont.)
• Combination wrench
• Use box end for initial loosening and the open end for final
loosening.

31. Use of Hand Tools (Cont.)
• Torque wrench
• Use to tighten fasteners to manufactures specifications.
• Requires special maintenance procedures to maintain their
calibration.

32. Use of Hand Tools (Cont.)
• Pipe wrench
• Specifically made to be used on tubing.
• Do not use “cheater bars” on pipe wrenches.
• Never use a pipe wrench on a nut or bolt.
• Do not use a pipe wrench on soft fittings.

33. Use of Hand Tools (Cont.)
• Pliers
• Beware of pinch points.
• Do not use as a substitute for a wrench.

34. Use of Hand Tools (Cont.)
• Spark resistant
• Use around flammable materials.
• Spark resistant tools only reduce spark-related hazards, they do
NOT eliminate them.

35. Use of Hand Tools (Cont.)
• Soldering irons
• Use proper PPE (to avoid burns, inhalation, lead, etc.).
• Use holders that completely surround the heating element.

36. Portable Power Tools
• Power sources for portable power tools (five primary
groups):
• electrical
• pneumatic
• gasoline
• hydraulic
• powder actuated

37. Hazards and Safety Precautions
• Power tools share many of the same hazards as hand
tools; however, the power source adds additional energy
output, which may lead to more serious incidents.
• Portability factor makes it difficult to use proper guarding.
• Electrical cords and air hoses present tripping hazards.
• Materials should be secured, prior to using power tools.
• Workers must use the proper PPE.

38. Selecting Power Tools
• Using power tools to replace hand tools presents
additional hazards.
• It is important to consider the work site, use, timeframe,
etc., when making your selection.
• Always choose a tool that is of sufficient size/capacity to
perform the given job.

39. Inspection and Repair
• All power tools must be inspected and repaired on a
routine basis.
• Inspect electrical tools as specified by the OSHA electrical
safety-related work standard.
• Use non-flammable solvents to clean tools.
• Maintenance and repairs should be performed by an
authorized and qualified worker.

40. Electrical Tools
• Electrical shock is one of the primary hazards.
• The ratio of voltage and resistance determines the
amount of current that will flow and the resultant degree of
hazard.
• Grounding and using a GFCI are effective ways to reduce
the chance of shock.

41. Electrical Cords
• Inspect cords prior to use.
• Instruct employees not to jerk cords or wind them too
tight.
• Cords should be protected from sharp objects, heat, and
oil, or other solvents.
• Use the proper wire size for electrical current needs.

42. Electric Drills
• Causes of injuries:
• torque and twisting of the tool
• part of drill penetrates the worker’s body
• tool dropped by worker
• flying debris or broken drill bits
• eye protection

43. Electric Drills (Cont.)
• Incident prevention:
• Be sure the trigger switch works properly.
• Check for loose power-cord connections and damage to cord.
• Be sure the chuck is secured to the spindle.
• Use proper PPE (safety goggles or glasses with side shields).
• Hold and brace the tool securely.
• Do not use the cord to raise or lower the drill.

44. Electrical Circular Saws
• Guards must be in place and functioning properly.
• OSHA requirement: >90 volts must be grounded.
• Always use sharp blades.
• Use both hands to control the saw.
• Prior to cutting, the saw should reach full speed.
• Be aware of kickback dangers.

45. Reciprocating Saw
• It is vital that the proper blade length be used for the job.
• Avoid cutting above shoulder height.
• Do not remove the blade from the material until the blade
has stopped.

46. Miter Saw
• Use proper PPE.
• In some cases it is not recommended to wear gloves.
• Never place hands in path of blade.
• Lock the miter head in the down position when not in use.

47. Jig/Saber Saws
• Do not plunge cut without first drilling a pilot hole.
• Do not remove the blade from the material until it has
stopped.

48. Rotary Die Grinder
• Use proper PPE.
• Air sampling may be necessary.
• Inspect the cutting wheel prior to use.

49. Sanders
• Be aware of burn hazards.
• Sparks may ignite flammable materials.
• Be aware of dust accumulation.

50. Routers
• Only use sharp bits.
• Use both hands to operate the tool.
• Secure all materials prior to use.

51. Air-Powered Tools
• Air hose
• Presents a tripping or stumbling hazard.
• Do not allow workers to disconnect the air hose and use it to
blow off their person or machine.
• Shut the air supply off prior to disconnecting.
• A small chain should be attached to the air hose next to the
couplings to prevent “air hose whipping.”

52. Pneumatic-Impact Tools
• Noise is a common hazard. Use proper PPE.
• Require two safety devices:
• Automatic closing valve, activated by the trigger.
• Retaining device used to prevent the tool from unintentional firing
from the barrel.
• If more than one chipper is working in the same vicinity;
they should work back to back to prevent face cuts from
flying chips.

53. Power Nailer
• Powered by compressed air, some are electric, others use
gas fuel cartridge, or batteries. Gas fuel must be used in
well-ventilated areas.
• Use the proper level of air pressure.
• Workers should not place their finger on the trigger until
they are ready to fasten the material.

54. Specialty Tools
• Chain saws present unique hazards that must be
mitigated:
• kickback
• vibration
• cutting
• burns from mufflers
• flying debris
• muffler ignites ground material
• refueling explosions

55. Personal Protective Equipment
• Employees should wear eye and face protection where
flying particles present a hazard.
• Do not overlook eye protection on the following jobs:
• cutting wire or cable
• striking wrenches
• using hand drills
• chipping concrete
• shoveling material
• removing nails from lumber
• working on the leeward side of a job
• using wrenches and hammers overhead
• debris falling