TITLE:	ES&H Manual
DOCUMENT ID:	6120 Hand Powered Tools

1.0 Introduction

The safest tool is the one made for the job, and used as designed. At Jefferson Lab, tools are only to be used in ways intended by the manufacturer. “Creative” use or misuse of tools often leads to injury or a damaged product.

For example, an adjustable wrench can tighten a nut, but it would be better to use a box-end wrench or a socket wrench of the proper size. Ergonomically designed tools, of course, provide the best fit for the employee and the job.

2.0 Hazard Avoidance

Select the Right Tool

When selecting a tool, consideration should be given to the job, the worker, the setup, the work space, access to the work space, the work height, and the correct tool size.

Keep Tools in Good Condition

Examine every tool before each use. Employees responsible for the tool box/crib, and workers using tools on the job, should be taught how to check equipment so worn or damaged items can be repaired or removed from service.

Use Tools Correctly

Follow all labels and manufacturer’s recommendations when using tools, and always use the proper personal protective equipment (PPE).

Store Tools in a Safe Place

Tools need to be stored properly, either in the work area or in a common tool box/crib.

Use Appropriate PPE

(See ES&H Manual Chapter 6620 Personal Protective Equipment for more information.)

3.0 Responsibilities

Employees

• selecting the proper tool for the job
• checking to ensure that the tool is in good working condition
• using the tool correctly, including proper use of PPE
• cleaning and storing the tool properly

Supervisors/Sponsors/ Subcontracting Officer’s Technical Representatives (SOTRs)

• orienting an employee to his/her job and tools
• providing adequate training for the use of any tool used by an employee
• ensuring that the tool is used correctly and in conjunction with the appropriate PPE
• ensuring that the correct tool is available

4.0 Safe work practices

Cutting Tools

• When using cutting tools, normally, the direction of force should be away from the body; however, use the tool as it is designed to be used (i.e., cable stripping tools).
• All cutting tools used at Jefferson Lab must have a handle: this precludes the use of both single and double edge razor blades that are not secured in an approved holding device. Check with your supervisor if you have questions concerning the adequacy of a tool.
• PPE, such as safety glasses and hearing protection may be required for power cutting tools (i.e., band saws). Again check with your supervisor or any Environmental, Safety, Health, and Quality (ESH&Q) staff for guidance concerning PPE (refer to ES&H Manual Chapter 6620 Personal Protective Equipment).
• For hack saws, correctly place blades in the frame. This includes selecting the proper blade for the cutting task, adjusting the tension of the blade, and installing the blade with the teeth pointing forward.
• Use guide-blocks to guide materials across cutting surface.
• Use cut-resistant gloves and safety glasses whenever appropriate.
• Replace guards if they become damaged.
• Use retractable-blade utility knives.

Torsion Tools

Wrenches

• Use a short, steady pull with a wrench. Do not push.
• Check for secure footing and plenty of clearance for fingers.
• Wrenches should not be hammered or struck.
• Do not use extensions on handles for additional leverage.

Socket Wrenches

· Use, if possible, in place of an adjustable wrench or an open-ended wrench as they are safer and protect the bolt head or nut.

Adjustable Wrenches

· Use mainly for nuts and bolts that do not fit a standard wrench.

· Always apply pressure to the fixed-jaw side of the wrench and, whenever possible, pull the wrench toward the body.

Pipe Wrenches

· Both straight and chain-tong wrenches should have sharp jaws and should be kept clean to prevent slipping.

· Do not use a pipe wrench on nuts or bolts

· Do not hammer a pipe wrench unless it is specifically designed for such use.

· Do not use a pipe wrench as a hammer.

Torque Wrenches

· Good care of a torque wrench is important to ensure accurate measurements.

· Cleanliness of the bolt or nut threads is important.

· Torque wrenches should have a documented calibration test performed annually.

· Exceeding its scale range will likely damage its calibration accuracy.

Side Cutting Pliers

· Electricians’ pliers should be insulated and the insulated grips should be replaced as needed.

· The use of safety glasses with side shields will help prevent eye injuries.

· Jaw serrations should be sharp enough to hold wires securely.

Screwdrivers

· Keep tips clean and square-edged. It is acceptable to reshape minor wear with a file.

· The tip should fit snugly in the screw.

· Dispose of any screwdriver with a broken or loose handle, bent blade, or dull or twisted tip.

· Never use any screwdriver for electrical work unless it is insulated. Be alert for small cracks in the insulation.

· Always make a pilot hole for a screw.

· Do not carry screwdrivers in your pockets.

· Do not use as a punch, wedge, pinch, or pry bar.

Vises

· Fasten securely to a sturdy, immobile work bench or a similar base.

· When sawing material held in a vise, make the cut as close to the jaws as possible.

· If clamping long pieces, support the free end of the piece adequately.

Clamp

· Over tightening a clamp can break the clamp or damage the product.

· If there is a swivel, it must turn freely.

· Clamps should be stored on a rack and not in a drawer

Impact Tools

Hammers

· Hammers may chip or spall depending on:

o the number of square corners

o the force of impact

o the hardness of the hit surface or object

o the angle of impact

· Handles should be fitted securely to the head, should be smooth, free of oil, and shaped to fit the hand.

· Hammer heads should be dressed whenever they start to mushroom. Take mushroomed hammers to the machine shop for dressing.

· When using a hammer, wear safety glasses.

· Never hit two hammer heads together.

· Do not use a claw hammer to strike another tool; use a ball-peen or maul hammer.

Sledge Hammers

· Do not use a sledge hammer with a split handle or a chipped head.

· Use proper PPE (face shield).

Portable Power Tools

A portable power tool presents hazards similar to a stationary machine of the same kind. Due to the mobility of power-driven tools, they can easily come in contact with the operator’s body. Generally:

• Be sure that the power source is “off” or unplugged (so the tool cannot inadvertently become powered up) before making adjustments to a power tool: bit or blade replacement, for example.
• Do not wear loose clothing, jewelry, ties, or any dangling objects, including long hair that may catch in rotating parts or accessories.
• If it has an electrical cord, constantly stay aware of the cord’s location.
• Make sure removable parts are in good condition and securely attached to the power tool before use.

Electric tools

Electric shock is the chief hazard from electrically-powered tools. For that reason:

· Do not use electric tools in damp or wet areas or in metal tanks.

· Only use electric tools that are in good repair.

· Only use double-insulated electric tools. However, if a double-insulated tool is not available, a ground-fault circuit-interrupter (GFCI) must be used.

· GFCIs must be used where civil construction activities are occurring and in wet environments.

Circular saws

Eye protection meeting ANSI Z87.1 standards shall be worn when operating a circular saw. Such eyewear is available from the stockroom.

Guards should be used as the manufacturer intended. The guard should be checked frequently to be sure that it operates freely and encloses the teeth completely when cutting. It should also enclose the unused portion of the blade when it is cutting.

· Do not use a circular saw that is too heavy for a worker to easily control.

· Be sure that the switch turns the tool on and returns to the off position after release.

· Use sharp blades.

· Use the correct blade for the application, and observe rotation marks on the blade during installation.

· Check these points carefully:

o Does the blade have the proper size and shape arbor hole?

o Is the speed marked on the blade at least as high as the no-load speed (revolutions per minute) on the saw’s nameplate?

· The work piece must be securely clamped.

· For maximum control, use both hands or a guide block to properly and safely guide the saw.

Extension cords

· Use only three-prong, grounding-type plugs and three-pole receptacles that accept the tool’s plug.

· Do not use an undersized cord, as it will overheat and can cause damage to the tool motor.

· Consider the type of tool used and the length of extension needed. If you are unsure about the gauge of wire to use, contact your supervisor or ESH&Q staff for assistance.

· Use only UL-approved extension cords (hard service cords, rated SO or SJ).

Abrasive wheels, buffers, and scratch brushes

Always wear eye protection; this is a requirement.

Abrasive tools should be guarded as completely as possible. For grinding, the maximum angular exposure of the periphery and sides should not exceed 180 degrees. The top portion of the wheel should always be enclosed. Guards should be adjustable so operators will be inclined to make the correct adjustment instead of removing the guard.

· An abrasive wheel should be kept away from water and oil, which might affect its balance.

· Protect the wheel from blows by other tools, and avoid striking the sides of a wheel against other objects or dropping the wheel.

· Employees should be trained to hold and use the wheel correctly so that it does not touch their clothes or body.

· Only trained employees should install the wheels.

· Guards for wheels must not be removed.

· Wheels should be sound-tested (ring-tested) before being mounted. Discard defective wheels immediately.

· Ensure that maximum machine rotation (RPM) does not exceed the rating of the wheel.

Belt or Disc Sanders

· With portable sanders, be careful not to expose the tool to liquids, or use in damp, wet locations.

· When adjusting the tracking of the belt on a portable sander, be certain that you have the sander supported and positioned to avoid accidental contact with yourself or an adjacent object.

· The work area should be at least 3ft – 4ft larger than the length of stock being sanded.

· •Use jigs, clamps, or fixtures to hold your work piece whenever possible.

Stationary Sanders:

· maintain a 1/16 in. maximum clearance between the work table and the sanding disc or belt on all working sides.

· always support your work piece with the table or backstop.

Disc Grinders

· Portable straight grinders should be used only with high-strength, bonded wheels.

· Tuck point grinders are a variation of straight grinders and should be equipped with reinforced abrasive discs and the appropriate guard.

· Maintain firm control of the tool.

· Never over reach.

· Carefully maintain balance of the machine.

· Do not allow the grinding wheel to bend, pinch, or twist in the cut because kickback may result.

· Angle grinders are primarily used with reinforced abrasive discs or wire cup brushes for the removal of metal or masonry.

· Use of proper combination of wheel and guard is critical.

· User must follow manufacturer's recommendations contained in the owner/operator's manual.

· Do not use damaged grinding wheels.

· Watch for hot fragments thrown off the material. This is likely to be a fire hazard job; see ES&H Manual Chapter 6122 Welding, Cutting, Brazing, and Grinding for more information.

Air Powered Tools

Air powered grinders require the same kind of guarding as electric grinders. Be sure the speed regulator or governor on these machines is carefully maintained to avoid wheel runaway.

Operators of air tools should:

· Keep hands and clothing away from the working end of the tool.

· Follow safety requirements applicable to the tool being used and the nature of the work being performed.

· Inspect and test the tool, air hose, and coupling before each use.

· Use a short chain or wire to secure all air line couplings.

· Never exceed the manufacturer’s listed air pressure for the tool.

Pneumatic Tools

Jackhammers

Handling heavy jackhammers causes fatigue and strain. Jackhammer handles should be covered with heavy rubber grips to reduce vibration and user fatigue, and operators should wear safety shoes to reduce the possibility of injury should the hammer fall. When two jackhammers are in use, workers should work back-to-back, to prevent face cuts from flying chips.

Hearing protection and eye protection with side shields are required when using or working within 20 ft of an operating jackhammer.

Powder Actuated Fastening Tools

The hazards encountered in the use of these tools are similar to those encountered with firearms. The handling, storing, and control of explosive cartridges present additional hazards. (See OSHA 1919.243(d) and the National Safety Council Data Sheet 236, Powder Actuated Hand Tools).

Operators must be trained by a representative of the tool manufacturer.

4.0 References:

ANSI Standard B7.1 Safety Requirements for Use, Care, and Protection of Abrasive Wheels

OSHA 1910.261 (C) (13) Hand Tools 1910.261 (B) 1 Guards 1910.222 Subpart P Hand and Portable Powered Tools and Other Hand Held Equipment 1910.243 Guarding of Portable Powered Tools

ISSUING AUTHORITY	CHAPTER AUTHOR	APPROVAL DATE	EFFECTIVE DATE	EXPIRATION DATE	REV.
ESH&Q Division	Ned Walker	03/16/05	03/16/05	03/16/08	0

This document is controlled as an on line file. It may be printed but the print copy is not a controlled document. It is the user’s responsibility to ensure that the document is the same revision as the current on line file. This copy was printed on 8/25/2009.