12 Aug Hand Tool Use – JSA

Hand Tool Use Job Safety Analysis (JSA)

Job / Task

Selection, inspection, use, handling, transport, maintenance, and storage of non-powered hand tools, including hammers, wrenches, screwdrivers, pliers, cutters, chisels, punches, files, saws, utility knives, pry bars, and similar tools.

Purpose

This Job Safety Analysis (JSA), also known as a Job Hazard Analysis (JHA), identifies hazards associated with hand tool use and establishes safe work practices and controls to prevent cuts, punctures, struck-by injuries, flying particles, pinch points, strains, slips, falls, and injuries caused by damaged, improperly selected, or misused tools.

Personnel Qualifications

Employees using hand tools shall be trained in the safe selection, inspection, use, and storage of the tools required for their assigned work. Specialized tools shall be used only by employees who understand their intended use and limitations.

Employees shall:

• Select the correct tool, size, and type for the task.
• Inspect tools before use and remove damaged or defective tools from service.
• Use tools only for their intended purpose and in accordance with manufacturer instructions.
• Maintain secure footing and proper body positioning while using tools.
• Keep hands and other body parts out of the tool’s path and line of fire.
• Secure workpieces when movement could create a hazard.
• Use required eye, face, hand, and other personal protective equipment.
• Maintain tools in safe condition and store them properly after use.
• Stop work when the correct tool or required protective controls are unavailable.

Required PPE

PPE shall be selected based on the tool, material, and task and may include:

• Safety glasses with side protection.
• Face shield worn over safety glasses or goggles where flying particles or fragments present a significant face hazard.
• Work gloves appropriate to the material and task, provided they do not create an entanglement or loss-of-control hazard.
• Cut-resistant gloves where appropriate for sharp materials or cutting tasks.
• Safety footwear appropriate for dropped tools, sharp materials, or construction hazards.
• Hard hat where overhead or construction hazards exist.
• Hearing protection where the task creates hazardous noise.
• Additional task-specific PPE identified by the hazard assessment.

JSA – Job Steps, Hazards, and Controls

Step 1 – Evaluate the Task

Potential Hazards

• Wrong tool selection.
• Unexpected material movement.
• Flying particles.
• Excessive force.

Required Controls

• Identify the work to be performed, material involved, access, and expected tool forces.
• Select a tool designed for the intended task rather than improvising.
• Determine whether a powered or mechanical tool would reduce excessive force or ergonomic exposure.
• Identify nearby personnel, equipment, energized systems, and other hazards.
• Plan the work so hands and body parts remain outside the anticipated line of fire.

Step 2 – Select the Correct Tool

Potential Hazards

• Tool slipping.
• Tool breakage.
• Damaged fasteners or workpiece.
• Excessive strain.

Required Controls

• Use the correct type and size of tool for the fastener, material, and operation.
• Do not substitute pliers for a wrench, a screwdriver for a chisel, or other tools for purposes for which they were not designed.
• Use insulated, non-sparking, or other specialty tools when specifically required by the hazard.
• Do not use makeshift extensions or cheater bars unless the tool and method are specifically designed and approved for that use.
• Obtain the proper tool before proceeding when the correct tool is unavailable.

Step 3 – Inspect the Tool Before Use

Potential Hazards

• Tool failure.
• Flying fragments.
• Cuts or punctures.
• Loss of control.

Required Controls

• Inspect handles, heads, jaws, cutting edges, tips, shafts, and other components before use.
• Check for cracks, mushroomed heads, loose handles, excessive wear, deformation, corrosion, or other damage.
• Verify adjustable tools operate smoothly and lock or adjust as designed.
• Inspect cutting tools for damaged, dull, or improperly installed blades.
• Tag or otherwise remove defective tools from service.

Step 4 – Prepare the Work Area

Potential Hazards

• Slips and trips.
• Poor lighting.
• Struck-by exposure.
• Restricted movement.

Required Controls

• Maintain adequate lighting and sufficient working space.
• Remove unnecessary tools, debris, cords, hoses, and materials from the immediate work area.
• Keep walking and working surfaces clean and dry where practical.
• Control access when tool use may expose nearby employees to flying particles or struck-by hazards.
• Maintain a stable working position before applying force.

Step 5 – Secure the Workpiece

Potential Hazards

• Workpiece movement.
• Pinched fingers.
• Tool slipping.
• Cuts.

Required Controls

• Secure small or movable workpieces with a vise, clamp, fixture, or other suitable method when necessary.
• Do not hold work by hand when foreseeable movement could place the hand in the tool path.
• Support long or awkward materials to prevent unexpected movement.
• Position clamps and supports so they do not interfere with tool use.
• Verify the workpiece is stable before beginning.

Step 6 – Use Hammers and Striking Tools

Potential Hazards

• Flying fragments.
• Hand injury.
• Tool-head separation.
• Struck-by injury.

Required Controls

• Use a hammer of the correct type, size, and striking-face hardness for the task.
• Inspect handles and heads for looseness, cracks, splitting, or damage.
• Do not use striking tools with mushroomed, chipped, or excessively deformed striking surfaces.
• Keep hands clear of the striking area and use holding devices where practical for small punches or chisels.
• Wear appropriate eye and face protection where fragments or particles may be generated.

Step 7 – Use Wrenches and Sockets

Potential Hazards

• Slipping wrench.
• Knuckle injuries.
• Pinch points.
• Overexertion.

Required Controls

• Use the correct size and type of wrench or socket.
• Ensure the tool is fully seated on the fastener before applying force.
• Pull on a wrench rather than push when practical and when doing so provides better control.
• Maintain balanced footing and anticipate sudden release of tight fasteners.
• Do not use damaged, spread, cracked, or excessively worn wrench jaws or sockets.

Step 8 – Use Screwdrivers

Potential Hazards

• Puncture injury.
• Tool slipping.
• Eye injury.
• Electrical contact.

Required Controls

• Use the correct tip type and size for the screw.
• Do not use a screwdriver as a punch, chisel, pry bar, or wedge.
• Do not hold the workpiece in a hand directly behind the screwdriver tip.
• Use tools specifically rated and designed for electrical exposure when such work is authorized and required.
• Replace screwdrivers with damaged tips, shafts, or handles.

Step 9 – Use Pliers and Cutters

Potential Hazards

• Pinched fingers.
• Flying wire ends.
• Cuts.
• Tool breakage.

Required Controls

• Use pliers and cutters designed for the material and operation.
• Keep fingers clear of jaws and cutting edges.
• Control or shield wire ends and other materials that may fly when cut.
• Do not exceed the tool’s cutting capacity.
• Do not use pliers as hammers or wrenches unless specifically designed for that purpose.

Step 10 – Use Chisels and Punches

Potential Hazards

• Flying metal fragments.
• Mushroomed heads.
• Hand injuries.

Required Controls

• Inspect striking heads and cutting points before use.
• Remove from service chisels or punches with mushroomed or cracked heads until properly repaired or replaced.
• Use hand protection and holding tools where appropriate.
• Direct the tool away from yourself and others.
• Use eye and face protection appropriate to the flying-particle hazard.

Step 11 – Use Files and Rasps

Potential Hazards

• Puncture from exposed tang.
• Cuts.
• Workpiece movement.

Required Controls

• Use files and rasps with properly fitted handles when the tang could create an injury hazard.
• Secure the workpiece when necessary.
• Apply controlled pressure and maintain stable footing.
• Do not use a file as a pry bar or striking tool.
• Clean files using an appropriate file card or other suitable method rather than bare hands.

Step 12 – Use Utility Knives and Cutting Tools

Potential Hazards

• Lacerations.
• Punctures.
• Blade breakage.
• Cuts to nearby employees.

Required Controls

• Use the correct cutting tool and blade for the material.
• Inspect the handle, blade-retention mechanism, and blade before use.
• Cut away from the body and keep the free hand out of the cutting path.
• Use a stable cutting surface and avoid excessive force.
• Retract, sheath, or otherwise protect the blade when not in use and dispose of used blades in an appropriate container.

Step 13 – Use Hand Saws

Potential Hazards

• Cuts.
• Blade binding.
• Workpiece movement.
• Overexertion.

Required Controls

• Select the correct saw and blade for the material.
• Inspect the blade, frame, handle, and blade tension before use.
• Secure the workpiece and keep the free hand away from the cutting path.
• Begin cuts in a controlled manner and avoid excessive force that may cause binding or blade failure.
• Store saws so teeth and blades do not create contact hazards.

Step 14 – Use Pry Bars and Levers

Potential Hazards

• Sudden release.
• Crushing.
• Struck-by injury.
• Loss of balance.

Required Controls

• Use a pry bar of adequate size and strength for the task.
• Verify the fulcrum and contact points are stable before applying force.
• Keep the body out of the anticipated path of the bar and load if the tool slips or releases.
• Do not use pipe, makeshift bars, or damaged tools as substitutes.
• Use mechanical lifting equipment when the required force or load cannot be safely controlled.

Step 15 – Work Near Electrical Hazards

Potential Hazards

• Electric shock.
• Arc flash.
• Unexpected energization.

Required Controls

• Identify electrical hazards before beginning work.
• De-energize and apply required energy-control procedures before working on or near hazardous electrical parts whenever required.
• Use properly rated insulated tools only when appropriate to the authorized electrical task.
• Keep conductive hand tools away from exposed energized parts unless required controls are in place.
• Do not assume a tool with a plastic or rubber handle is electrically insulated.

Step 16 – Work at Heights with Hand Tools

Potential Hazards

• Dropped tools.
• Falls.
• Struck-by injuries below.

Required Controls

• Maintain required fall protection and safe access.
• Use tool bags, buckets, holsters, or other suitable means to transport tools.
• Do not carry tools in a manner that interferes with safe climbing or required handholds.
• Secure tools against falling where dropped-object hazards exist and where required.
• Barricade or control areas below when falling tools could expose personnel.

Step 17 – Maintain Safe Body Position and Force

Potential Hazards

• Strains and sprains.
• Loss of balance.
• Sudden tool release.

Required Controls

• Maintain stable footing and position the body to remain balanced if the tool slips or the load releases.
• Avoid excessive reaching, twisting, and awkward postures.
• Use both hands where appropriate for tool control.
• Do not apply excessive force to compensate for a dull, damaged, or incorrect tool.
• Take breaks, reposition the work, or use mechanical assistance when repeated force creates excessive strain.

Step 18 – Transport Hand Tools

Potential Hazards

• Cuts or punctures.
• Dropped tools.
• Trips.
• Injury while climbing.

Required Controls

• Carry sharp or pointed tools in a sheath, tool bag, box, or other protective manner.
• Do not carry sharp tools in pockets unless specifically protected.
• Use tool bags, buckets, or hoisting methods when climbing ladders or accessing elevated areas.
• Keep aisles and access routes clear while moving tools.
• Do not throw tools between employees or between work levels.

Step 19 – Clean and Maintain Tools

Potential Hazards

• Cuts.
• Exposure to damaged surfaces.
• Improper repairs.

Required Controls

• Clean tools using methods appropriate to the tool and contamination.
• Sharpen and maintain cutting edges using proper equipment and procedures.
• Do not make unauthorized modifications or makeshift repairs.
• Replace damaged handles, blades, or components with suitable parts.
• Remove tools from service until required repairs are completed.

Step 20 – Store Tools After Use

Potential Hazards

• Cuts and punctures.
• Falling tools.
• Trip hazards.
• Tool damage.

Required Controls

• Return tools to designated storage locations after use.
• Store sharp edges and points so they are protected from accidental contact.
• Do not leave tools on ladders, scaffolds, elevated surfaces, walkways, or equipment where they may fall or create a trip hazard.
• Keep toolboxes, cabinets, and storage areas organized.
• Report and segregate defective tools so they are not inadvertently returned to service.

General Safe Work Requirements

• The correct tool shall be selected for each task and used only for its intended purpose.
• Hand tools shall be inspected before use and maintained in safe condition.
• Damaged, defective, excessively worn, or improperly modified tools shall be removed from service.
• Tools shall not be thrown, dropped between levels, or carried in a manner that creates a cut, puncture, or falling-object hazard.
• Workpieces shall be secured when movement could expose employees to injury.
• Employees shall keep hands and body parts out of cutting, striking, pinch, and line-of-fire zones.
• Required guards, handles, attachments, and safety features shall not be removed or bypassed.
• Appropriate eye and face protection shall be used where flying particles, fragments, or chips may be generated.
• Tools used around electrical hazards shall be appropriate and properly rated for the task.
• Tools used at elevation shall be controlled to prevent dropped-object hazards.
• Good housekeeping shall be maintained during and after tool use.
• Work shall stop whenever the correct tool, required PPE, adequate access, or other necessary controls are unavailable.

Training

Employees who use hand tools shall receive training appropriate to the tools and tasks assigned. Training shall include tool selection, pre-use inspection, proper use and limitations, striking-tool hazards, cutting-tool safety, line-of-fire and pinch-point awareness, workpiece securing, electrical hazards, dropped-object prevention, PPE, maintenance and storage, ergonomic considerations, and removal of defective tools from service.

References

• OSHA 29 CFR 1926.300 – General Requirements for Tools.
• OSHA 29 CFR 1926.301 – Hand Tools.
• OSHA 29 CFR 1910.242 – Hand and Portable Powered Tools and Equipment, General, where applicable.
• Applicable manufacturer instructions and site-specific tool safety requirements.