Power & Hand tool safety

PEOPLE MAKE PLACES

1
 Power Tools Serious Accident
Last January 2006 in Indonesia, a worker was
cutting aluminium roofing sheets using a grinder,
the grinder’s wheel broke apart and hit his face
causing serious injury between his upper lips
and nose.

After first aid treatment heJjkkjnnnbnm was sent

to Hospital for further treatment. The doctor at
the Hospital recommended he be hospitalised for
about two weeks!
2
PEOPLE MAKE PLACES
 Power Tools Serious Accident
● Based on manufacturer
specification, Makita grinder model
9006B should use 6” grinding
wheel, speed load 10,000 RPM.
● 9.5” grinding wheel was used
instead of using 6” grinding wheel.
● This wheel was oversized and
designed to be run at 3400 RPM.
● Grinding wheel was running at
10,000 RPM causing the wheel fly
apart and hit the mechanic’s face.
● What Went Wrong
- Utilised improper tool.
- No grinder safety guard.
- Not using face shield for PPE.

3
PEOPLE MAKE PLACES
 Hazards
Workers using hand and
power tools may be exposed
to these hazards:
• Objects that fall, fly, are
abrasive, or splash
• Harmful dusts, fumes, mists,
vapors, and gases
• Frayed or damaged electrical
cords, hazardous
connections and improper
grounding

4
PEOPLE MAKE PLACES
 Basic Tool Safety Rules
● Maintain regularly
● Use right tool for the job
● Inspect before use
● Operate according to
manufacturers’
instructions
● Use the right personal
protective equipment
(PPE)
● Use guards

5
PEOPLE MAKE PLACES
 Hand Tool Hazards
Hazards are usually caused by
misuse and improper maintenance

Do not use;
• Wrenches when jaws are sprung
• Tools with taped handles – they Crac
may be hiding cracks k
• Tools with loose, cracked or
splintered handles
• Impact tools (chisel and wedges)
when heads have mushroomed
Mushroom Head
• A screwdriver as a chisel

6
PEOPLE MAKE PLACES
 Electricity - The Dangers
● About 5 workers are
electrocuted every week
● Causes 12% of young
worker workplace deaths
● Takes very little electricity
to cause harm
● Significant risk of causing
fires

7
PEOPLE MAKE PLACES
 Electricity – How it Works
● Electricity is the flow of
energy from one place to
another
● Requires a source of power:
usually a generating station
● A flow of electrons (current)
travels through a conductor
● Travels in a closed circuit

8
PEOPLE MAKE PLACES
 Electrical Terms
● Current -- electrical movement (measured in amps)
● Circuit -- complete path of the current.
Includes electricity source, a conductor, and the output
device or load (such as a lamp, tool, or heater)
● Resistance -- restriction to electrical flow
● Conductors – substances, like metals, with little
resistance to electricity that allow electricity to flow
● Grounding – a conductive connection to the earth
which acts as a protective measure
● Insulators -- substances with high resistance to
electricity like glass, porcelain, plastic, and dry wood
that prevent electricity from getting to unwanted areas
9
PEOPLE MAKE PLACES
 Electrical Injuries
There are four main types of electrical injuries:
● Direct:
1. Electrocution or death due to electrical
shock
2. Electrical shock
3. Burns
● Indirect:
4. Falls

10
PEOPLE MAKE PLACES
 Electrical Shock
An electrical shock is received when electrical
current passes through the body.

You will get an electrical shock if a part of your

body completes an electrical circuit by…

● Touching a live wire and an electrical ground, or

● Touching a live wire and another wire at a
different voltage.

11
PEOPLE MAKE PLACES
 Shock Severity
● Severity of the shock depends
on:
– Path of current through the body
– Amount of current flowing
through the body (amps)
– Duration of the shocking current
through the body,

● LOW VOLTAGE DOES NOT

MEAN LOW HAZARD

12
PEOPLE MAKE PLACES
 Dangers of Electrical Shock
● Currents above 10 mA can
paralyze or “freeze” muscles.
● Currents more than 75 mA
can cause a rapid,
ineffective heartbeat -- death
will occur in a few minutes
unless a defibrillator is used
● 75 mA is not much current –
a small power drill uses 30
times as much
Defibrillator in
13
PEOPLE MAKE PLACES
use
 Effects of Electrical Shock
1mA 5mA 10mA 15mA 50-100mA

Can paralyze
Slight Sensation of Can Kill In A
Shock
Painful or “freeze”
Second
Sensation muscles

14
PEOPLE MAKE PLACES
 Burns
● Most common shock-
related injury
● Occurs when you touch
electrical wiring or
equipment that is
improperly used or
maintained
● Typically occurs on hands
● Very serious injury that
needs immediate attention

15
PEOPLE MAKE PLACES
 Falls

● Electric shock can also

cause indirect injuries

● Workers in elevated
locations who experience
a shock may fall,
resulting in serious injury
or death

16
PEOPLE MAKE PLACES
 Electrical Hazards and How to
Control Them
Electrical accidents are
caused by a combination
of three factors:
• Unsafe equipment
and/or installation,
• Workplaces made
unsafe by the
environment, and
• Unsafe work practices.

17
PEOPLE MAKE PLACES
 Hazard – Exposed Electrical Parts

Cover removed from wiring or breaker box

18
PEOPLE MAKE PLACES
 Control – Isolate Electrical Parts

● Use guards or
barriers

● Replace covers

Guard live parts of electric

equipment operating at 50
volts or more against
accidental contact
19
PEOPLE MAKE PLACES
 Control – Isolate Electrical Parts -
Cabinets, Boxes & Fittings

Conductors going into them must be protected, and

unused openings must be closed
20
PEOPLE MAKE PLACES
 Control – Close Openings
● Junction boxes, pull
boxes and fittings
must have approved
covers
● Unused openings in
cabinets, boxes and
fittings must be closed
(no missing
knockouts) Photo shows violations
of these two requirements

21
PEOPLE MAKE PLACES
 Hazard - Overhead Power Lines
● Usually not insulated
● Examples of equipment that
can contact power lines:
• Crane
• Ladder
• Scaffold
• Backhoe
• Scissors lift
• Raised dump truck bed
• Aluminum paint roller

22
PEOPLE MAKE PLACES
 Control - Overhead Power Lines

● Stay at least 10 feet away

● Post warning signs
● Assume that lines are
energized
● Use wood or fiberglass
ladders, not metal
● Power line workers need
special training & PPE

23
PEOPLE MAKE PLACES
 Hazard - Inadequate Wiring
● Hazard - wire too small for the
current
● Example - portable tool with an
extension cord that has a wire too
small for the tool
Wire Gauge
• The tool will draw more current than
the cord can handle, causing
overheating and a possible fire WIRE
without tripping the circuit breaker
Wire gauge measures
• The circuit breaker could be the right wires ranging in size from
size for the circuit but not for the number 36 to 0 American
smaller-wire extension cord wire gauge (AWG)

24
PEOPLE MAKE PLACES
 Control – Use the Correct Wire
● Wire used depends on operation, building materials,
electrical load, and environmental factors
● Use fixed cords rather than flexible cords
● Use the correct extension cord

Must be 3-wire type and designed for

hard or extra-hard use
25
PEOPLE MAKE PLACES
 Hazard – Defective Cords & Wires

● Plastic or rubber
covering or
insulation is
missing

● Damaged
extension cords
& tools

26
PEOPLE MAKE PLACES
 Hazard – Damaged Cords
● Cords can be damaged by:
• Aging
• Door or window edges
• Staples or fastenings
• Abrasion from adjacent
materials
• Activity in the area
● Improper use can cause
shocks, burns or fire

27
PEOPLE MAKE PLACES
 Control – Cords & Wires
● Insulate live wires
● Check before use
● Use only cords that are 3-wire type
● Use only cords marked for hard or
extra-hard usage
● Use only cords, connection
devices, and fittings equipped with
strain relief
● Remove cords by pulling on the
plugs, not the cords
● Cords not marked for hard or
extra-hard use, or which have
been modified, must be taken out
of service immediately
28
PEOPLE MAKE PLACES
 Control – Cords & Wires
● Insulate live wires
● Check before use
● Use only cords that are 3-wire type
● Use only cords marked for hard or
extra-hard usage
● Use only cords, connection
devices, and fittings equipped with
strain relief
● Remove cords by pulling on the
plugs, not the cords
● Cords not marked for hard or
extra-hard use, or which have
been modified, must be taken out
of service immediately
29
PEOPLE MAKE PLACES
 Permissible Use of Flexible Cords
DO NOT use flexible wiring where
frequent inspection would be difficult
or where damage would be likely.

Flexible cords must not be . . .

• run through holes in walls, ceilings, or
floors;
• run through doorways, windows, or
similar openings (unless physically
protected);
• hidden in walls, ceilings, floors, conduit
or other raceways.
30
PEOPLE MAKE PLACES
 Grounding
Grounding creates a
low-resistance path
from a tool to the earth
to disperse unwanted
current.
When a short or
lightning occurs,
energy flows to the
ground, protecting you
from electrical shock,
injury and death.

31
PEOPLE MAKE PLACES
 Hazard – Improper Grounding

● Tools plugged into

improperly grounded
circuits may become
energized
● Broken wire or plug on
extension cord
● Some of the most
frequently violated
OSHA standards
32
PEOPLE MAKE PLACES
 Control – Ground Tools & Equipment
● Ground power supply
systems, electrical circuits,
and electrical equipment
● Frequently inspect electrical
systems to insure path to
ground is continuous
● Inspect electrical equipment
before use
● Don’t remove ground prongs
from tools or extension cords
● Ground exposed metal parts
of equipment

33
PEOPLE MAKE PLACES
 Control – Use GFCI (ground-fault
circuit interrupter)
● Protects you from shock
● Detects difference in current
between the black and white
wires
● If ground fault detected, GFCI
shuts off electricity in 1/40th of
a second
● Use GFCI’s on all 120-volt,
single-phase, 15- and 20-
ampere receptacles, or have
an assured equipment
grounding conductor program.
34
PEOPLE MAKE PLACES
 Control - Assured Equipment
Grounding Conductor Program
Program must cover:
• All cord sets
• Receptacles not part of a building or structure
• Equipment connected by plug and cord

Program requirements include:

• Specific procedures adopted by the employer
• Competent person to implement the program
• Visual inspection for damage of equipment connected
by cord and plug

35
PEOPLE MAKE PLACES
 Hazard – Overloaded Circuits
Hazards may result from:
● Too many devices plugged
into a circuit, causing heated
wires and possibly
a fire
● Damaged tools overheating
● Lack of over current
protection
● Wire insulation melting, which
may cause arcing and a fire in
the area where the overload
exists, even inside a wall

36
PEOPLE MAKE PLACES
 Control - Electrical Protective
Devices
● Automatically opens circuit if
excess current from overload
or ground-fault is detected –
shutting off electricity
● Includes GFCI’s, fuses, and
circuit breakers
● Fuses and circuit breakers
are overcurrent devices.
When too much current:
• Fuses melt
• Circuit breakers trip
open
37
PEOPLE MAKE PLACES
 Power Tool Requirements

• Have a three-wire cord with

ground plugged into a grounded
receptacle, or
• Be double insulated, or
• Be powered by a low-voltage
isolation transformer

38
PEOPLE MAKE PLACES
 Tool Safety Tips
● Use gloves and appropriate footwear
● Store in dry place when not using
● Don’t use in wet/damp conditions
● Keep working areas well lit
● Ensure not a tripping hazard
● Don’t carry a tool by the cord
● Don’t yank the cord to disconnect it
● Keep cords away from heat, oil, &
sharp edges
● Disconnect when not in use and when
changing accessories such as blades &
bits
● Remove damaged tools from use
39
PEOPLE MAKE PLACES
 Preventing Electrical Hazards - Tools

● Inspect tools before Double

use
GROUNDIN Insulation
Or
G

● Use the right tool

correctly
● Protect your tools
● Use double insulated
tools

Double Insulated marking

40
PEOPLE MAKE PLACES
 Temporary Lights

Protect from contact

and damage, and
don’t suspend by
cords unless
designed to do so.

41
PEOPLE MAKE PLACES
 Clues that Electrical Hazards Exist
● Tripped circuit breakers or
blown fuses
● Warm tools, wires, cords,
connections, or junction
boxes
● GFCI that shuts off a circuit
● Worn or frayed insulation
around wire or connection

42
PEOPLE MAKE PLACES
 Lockout and Tagging of Circuits
● Apply locks to power source
after de-energizing
● Tag deactivated controls
● Tag de-energized
equipment and circuits at all
points where they can be
energized
● Tags must identify
equipment or circuits being
worked on

43
PEOPLE MAKE PLACES
 Safety-Related Work Practices
To protect workers from
electrical shock:
• Use barriers and guards to
prevent passage through
areas of exposed energized
equipment
• Pre-plan work, post hazard
warnings and use protective
measures
• Keep working spaces and
walkways clear of cords
44
PEOPLE MAKE PLACES
 Safety-Related Work Practices
● Use special insulated
tools when working on
fuses with energized
terminals
● Don’t use worn or
frayed cords and
cables
● Don’t fasten extension
cords with staples,
hang from nails, or
suspend by wire.
45
PEOPLE MAKE PLACES
 Preventing Electrical Hazards -
Planning

• Plan your work with others

• Plan to avoid falls
• Plan to lock-out and tag-
out equipment
• Remove jewelry
• Avoid wet conditions and
overhead power lines

46
PEOPLE MAKE PLACES
 Avoid Wet Conditions
• If you touch a live wire or other
electrical component while
standing in even a small puddle
of water you’ll get a shock.
• Damaged insulation, equipment,
or tools can expose you to live
electrical parts.
• Improperly grounded metal switch
plates & ceiling lights are
especially hazardous in wet
conditions.
• Wet clothing, high humidity, and
perspiration increase your
chances of being electrocuted.
47
PEOPLE MAKE PLACES
 Preventing Electrical Hazards - PPE
● Proper foot protection
(not tennis shoes)
● Rubber insulating gloves,
hoods, sleeves, matting,
and blankets
● Hard hat (insulated -
nonconductive)

48
PEOPLE MAKE PLACES
 Preventing Electrical Hazards –
Proper Wiring and Connectors
• Use and test GFCI’s
• Check switches and
insulation
• Use three prong plugs
• Use extension cords only
when necessary & assure in
proper condition and right
type for job
• Use correct connectors

49
PEOPLE MAKE PLACES
 Training
Train employees working with electric
equipment in safe work practices, including:

● De-energize electric equipment before

inspecting or repairing
● Using cords, cables, and electric tools that
are in good repair
● Lockout / Tagout recognition and procedures
● Use appropriate protective equipment

50
PEOPLE MAKE PLACES
 Summary – Hazards & Protections
Hazard
● Inadequate wiring
● Exposed electrical parts
● Wires with bad insulation
● Ungrounded electrical
systems and tools
● Overloaded circuits
● Damaged power tools and
equipment
● Using the wrong PPE and
tools
● Overhead powerlines
● All hazards are made worse
51 in wet conditions
PEOPLE MAKE PLACES
Protective Measures
● Proper grounding
● Use GFCI
● Use fuses and circuit
breakers
● Guard live parts
● Lockout/Tagout
● Proper use of flexible
cords
● Close electric panels
● Training
 Summary
Electrical equipment must be:
• Listed and labeled
• Free from hazards
• Used in the proper manner
If you use electrical tools you must be:
• Protected from electrical shock
• Provided necessary safety equipment

52
PEOPLE MAKE PLACES
 Hand Tools - Protection

● Use PPE, such as safety

goggles, face shield and
gloves

● Keep floor surface where

working free from debris
and tripping or slipping
hazards

● Keep cutting tools sharp

53
PEOPLE MAKE PLACES
 Power Tools
● Must be fitted with guards
and safety switches (Dead
Man Switch)
● Extremely hazardous
when used improperly
● Different types,determined
by their power source:
⮚ Electric
⮚ Pneumatic
⮚ Liquid fuel
⮚ Hydraulic Dead Man Switch
⮚ Powder-actuated
54
PEOPLE MAKE PLACES
 Switches
Hand-held power tools must be
equipped with one of the
following:
Constant pressure switch
shuts off power upon release
Examples: circular saw, chain
saw, grinder, hand-held power
drill
On-Off Switch
Examples: routers, planers,
laminate trimmers, shears, jig
saws, nibblers, scroll saws

55
PEOPLE MAKE PLACES
 Power Tools - Precautions
● Disconnect tools when not in use, before servicing and
cleaning, and when changing accessories
● Keep people not involved with the work away from the
work
● Secure work with clamps or a vise, freeing both hands
to operate the tool
● Don’t hold the switch button while carrying a plugged-in
tool
● Keep tools sharp and clean
● Consider what you wear – loose clothing and jewelry
can get caught in moving parts
● Remove damaged electric tools & tag them: “Do Not
Use”

56
PEOPLE MAKE PLACES
 Power Tools – Precautions
Electric Cords

● Don’t carry portable tools

by the cord
● Don’t use electric cords to
hoist or lower tools
● Don’t yank cord or hose
to disconnect it
● Keep cords and hoses
away from heat, oil, and
sharp edges

57
PEOPLE MAKE PLACES
 Electric Power Tools

Plug with a
Double grounding
Insulation pin
Marks DOUBLE INSULATION
SYMBOL

To protect a worker from shock, these tools must:

• Have a 3-wire cord plugged into a grounded receptacle
• Be double insulated
• Be powered by a low-voltage isolation transformer
58
PEOPLE MAKE PLACES
 Electric Tools – Good Practices
• Operate within design limits
• Use gloves and safety shoes
• Store in a dry place
• Don’t use in wet locations
unless approved for that
• Keep work areas well lit
• Ensure that cords don’t
present a tripping hazard

59
PEOPLE MAKE PLACES
 Abrasive Wheels and Tools
● May throw off flying
fragments

● Equip with guards that:

- Cover the spindle end, nut,
& flange projections
- Maintain proper alignment
with the wheel
- Don’t exceed the strength
of the fastenings

● Guard so that a minimal

amount of the wheel is
exposed
60
PEOPLE MAKE PLACES
 Inspecting Abrasive Wheels
Before mounting:
• Inspect closely for damage
• Perform sound- or ring-test to
ensure free from cracks /
defects

To test:
• Tap wheel gently with a light,
non-metallic instrument
• If wheel sounds cracked or
dead, do not use it because it
could fly apart

61
PEOPLE MAKE PLACES
 Abrasive Wheel Use
● To prevent cracking:
- Fit the wheel on the spindle
freely
- Tighten the spindle nut
enough to hold the wheel in
place without distorting the
flange
● Let the tool come up to speed
prior to grinding or cutting
● Don’t stand in front of the
wheel as it comes up to full Ensure the spindle
speed speed doesn’t exceed
● Use eye and/or face the maximum speed
protection marked on the wheel

62
PEOPLE MAKE PLACES
 Abrasive Wheel Work Rests
● Keep work rests not more
than 1/8th inch from
wheel surface
● This prevents jamming
the work between the
wheel and the rest, which
may cause the wheel to
break
● Don’t adjust wheel while it
is rotating

63
PEOPLE MAKE PLACES
 Guarding
● Guard exposed moving
parts of power tools

● Guard belts, gears, shafts,

pulleys, sprockets,
spindles, flywheels,
chains, or other moving
parts

● Never remove a guard

when a tool is in use

64
PEOPLE MAKE PLACES
 Guarding - Point of Operation
This shows a radial arm saw equipped
with proper point of operation guards

The point of operation is where the work is actually

performed on the materials – it must be guarded
65
PEOPLE MAKE PLACES
 Guarding Protection
Machine guards
must protect the
operator and others
from:
Nip
• Point of operation Point Glass cover as
protection
• In-running nip points
• Rotating parts
• Flying chips and
sparks

66
PEOPLE MAKE PLACES
 Radial Saw Guarding
Radial arm saw
equipped with an upper
and lower blade guard

Guard to prevent the

operator from coming in
contact the the rotating
blade

67
PEOPLE MAKE PLACES
 Guarding Portable Circular Saws

Guard these saws

above and below
the base plate or
shoe. The lower
guard must cover
the saw to the
depth of the teeth.

68
PEOPLE MAKE PLACES
 Table Saw Guarding

Hood
guard

Use a hood for guarding

69
PEOPLE MAKE PLACES
 Pneumatic Tools
● Powered by compressed
air
● Includes nailers, staplers,
chippers, drills & sanders
● Main hazard - getting hit by
a tool attachment or by a
fastener the worker is using
with the tool
● Take the same precautions
with an air hose that you
take with electric cords

70
PEOPLE MAKE PLACES
 Pneumatic Tools - Fastening
● Ensure tool is fastened
securely to the air hose to
prevent a disconnection

● Use a short wire or

positive locking device
attaching the air hose to
the tool Wire used to secure
hose

71
PEOPLE MAKE PLACES
 Pneumatic Tool Connections

Low pressure High pressure

Hose clamps and connector

72
PEOPLE MAKE PLACES
 Pneumatic Tool Safety
● Place a safety device on the
muzzle to prevent the tool
from ejecting fasteners,
unless the muzzle is in
contact with work surface
● Install a safety clip or
retainer to prevent
attachments, such as
chisels on a chipping
hammer, from being ejected
● Wear eye protection. Wear
hearing protection with
jackhammers.

73
PEOPLE MAKE PLACES
 Compressed Air Cleaning
● Don’t use compressed
air for cleaning

● Exception - where
pressure is reduced to
less than 30 p.s.i. with
effective chip guarding
and PPE

74
PEOPLE MAKE PLACES
 Liquid Fuel Tools
● Usually gas powered

● Main hazard – fuel

vapors
● Use only approved
flammable liquid
containers
● Before refilling a
fuel-powered tool
tank, shut down the
engine and allow it
to cool

75
PEOPLE MAKE PLACES
 Powder-Actuated Tools
● User must be trained and
licensed to operate.
● Test tool each day before
loading to ensure the safety
devices are working properly.
● Wear suitable ear, eye, and
face protection.
● Select a powder level that will
do the work without excessive
force.

76
PEOPLE MAKE PLACES
 Fatal Fact
● Employee killed when
struck in head by a nail
fired from a powder
actuated tool.

● Tool operator was

attempting to anchor a
plywood form in
preparation for pouring
a concrete wall.

77
PEOPLE MAKE PLACES
 Easily Penetrated Material
Avoid driving into materials
easily penetrated unless
materials are backed by a
substance that will prevent
the pin or fastener from
passing through.

Also, don’t drive

fasteners into very hard
or brittle material that
might chip or splatter, or
make the fasteners
ricochet.

78
PEOPLE MAKE PLACES
 Powder-Actuated Tool Safety Tips
● Don’t use in explosive or flammable atmosphere
● Inspect tool before use to ensure:
⮚ it is clean,
⮚ that moving parts operate freely
⮚ the barrel is free from obstructions and has the
proper shield, guard, and attachments
● Don’t load the tool unless using immediately
● Don’t leave a loaded tool unattended
● Keep hands clear of the barrel end
● Never point the tool at anyone
● Store unloaded in a locked box

79
PEOPLE MAKE PLACES
 Hydraulic Jack
● To set up a jack, ensure:
⮚ The base is on a firm, level
surface
⮚ It’s centered
⮚ The jack head is placed
against a level surface
⮚ You apply the lift force evenly

● Lubricate and inspect jacks

regularly

80
PEOPLE MAKE PLACES
 Jacks - Blocking
Immediately block the load
after it is lifted. Put a block
under the base of the jack
when the foundation is not
firm, and place a block
between the jack cap and
load if the cap might slip.

Photo - handyman jack is

provided a firm base by using
the railroad tie.
The load is cribbed to prevent
it from falling.
81
PEOPLE MAKE PLACES
 Hydraulic Jack

● The manufacturer's rated

capacity must be marked
on all jacks and must not
be exceeded.

● All jacks must have a

stop indicator that should
not be exceeded.

82
PEOPLE MAKE PLACES
 Summary
Hazards are usually the result of improper tool
use or not following one or more of these
protection techniques:
⮚ Inspecting the tool before use
⮚ Usi
⮚ng PPE (Personal Protective Equipment)
⮚ Using protective guards
⮚ Properly storing the tool
⮚ Using safe handling techniques

83
PEOPLE MAKE PLACES