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1 AUSTRALIA CANADA USA UNITED KINGDOM SINGAPORE MALAYSIA Safetycare Australia Pty. Ltd. Telephone (03) Safetycare Inc. Telephone (905) Safetycare Inc. Telephone (800) Safetycare (UK) Limited. Telephone (0208) SafetyMax Corp Pte. Ltd. Telephone SafetyMax Sdn Bhd Telephone (603) The information contained in this Facilitator s guide is distributed and sold as a guide and for informational purposes only. Safetycare makes no representation or warranty as to the compliance of this program with any and all applicable laws of the purchaser's jurisdiction. 2. Safetycare's liability for any damages to the purchaser or to any other party shall not exceed the amount paid by the purchaser for the guide. In no event shall Safetycare be responsible for any indirect or consequential damages or loss of profits, even if Safetycare has been advised of the possibility of such damage. Some provinces/states do not allow the limitations or exclusion of liability for incidental or consequential damages, so the above limitations or exclusions may not apply to the purchaser. 3. This Facilitator s Guide is supplied as part of a subscription service. This guide is only to be used during a valid subscription period. Where a subscription is not valid, this guide may not be used. Facilitator s Guide HAND TOOLS SAFETY AND TECHNIQUE Copyright - All Rights Reserved

2 Hand Tools Safety and Technique CONTENTS Introduction to the Facilitator s Guide 3 Introduction to the Video Program; Hand Tools Safety and Technique 4 Transcript of Video Program 5 Part 1 - Spanners 12 Part 2 - Adjustable Spanner 13 Part 3 - Screwdrivers 14 Part 4 - Pliers 16 Part 5 - Hammers 17 Part 6 - Hacksaws 18 Assessment 20 Answers 22 2

3 INTRODUCTION TO THE FACILITATOR S GUIDE Hand Tools Safety and Technique The aim of this Facilitator s Guide, when used in conjunction with the Video program, is to provide the facilitator with discussion points important to the overall development of the program and to allow participants the opportunity of discussing the impact the program may have on current work practices and whether in fact changes may be required. The time allocated to the program will be determined by which areas are seen as important to each Organisation, the time taken to develop the points made in the program and whether other data specific to your own environment is included in addition to, or instead of, the program examples. EACH FACILITATOR SHOULD CAREFULLY READ THE GUIDE DISCUSSION NOTES SUGGESTED AND PREPARE THEIR OWN INPUT ACCORDINGLY. The program transcript is included to allow your Organisation to fully research the program content and develop specific examples critical to the performance of your own workforce. Where the Video program is made available to small or remote sections of your Organisation, some other examples or discussion points may be preferred to suit the needs of these people and if so, should be developed prior to distribution of the program. Maximum benefit will then be obtained by your people. All information included in the Facilitator s Guide may be copied and distributed with the exception of the transcript of the Video program. Any information which is copied or distributed must only be used internally by the Organisation that purchased the guide. SCREEN SHOT FROM THE VIDEO PROGRAM 3

4 INTRODUCTION TO THE VIDEO PROGRAM Duration: 15 minutes Basic Hand Tools are the most common equipment used throughout industry. However the correct, efficient and safe use of Hand Tools is sometimes lacking in the workplace. This program shows techniques and safe work practices relating to a wide range of basic Hand Tools including: Types and correct applications for Spanners Proper and safe use of pipe Wrenches A look at the wide range and types of Screwdrivers and their safe and correct usage The correct pair of Pliers for a particular task Hammers, their types and how to use them safely and correctly The correct use of Hacksaws and Blade types This program is aimed at all users of basic Hand Tools, whether they are students or experienced trades people who may require a refresher on safe and correct usage. 4

5 TRANSCRIPT OF THE VIDEO PROGRAM Hand Tools Safety and Technique Copyright Safetycare. All rights reserved Because everyone has had some experience with basic hand tools we are all aware of the wide range of uses to which they can be applied. This is because they are essentially simple machines designed with basic mechanical principles in mind. You provide the energy and they do the work. The aim of this program is to show the proper use and care of a number of basic hand tools. We will also look at safety procedures to keep in mind when you work with these tools. Believe it or not, you can learn from the tools themselves, the way they feel, ease of operation, even the sounds they make will tell you a great deal about the best way to use them. Spanners There are four basic types of spanners. Open-ended spanners can be either single or double ended. Tube spanners come with an associated 'Tommy Bar' and are useful for reaching nuts in recessed areas. Ring spanners, because of their round shape, are handy when obstructions crowd the sides of the nut. Socket spanners are versatile tools because of the wide range of accessories and adaptors available. Their design which incorporates from 4 to 12 points allows for a number of engaging positions. Of foremost concern in selecting the right spanner for a job is that the correct fit is achieved. Using a spanner which is not properly matched for the nut or bolt is not only dangerous to you but can also damage the spanner or nut making further work difficult. 5

6 The correct spanner for a particular job is determined by the size of the nut or bolt and the thread system. Even though the size discrepancy between conflicting systems may seem slight, any excess clearance runs the risk of the spanner slipping under pressure. This will result in damage and perhaps injury. Safety The safe use of a spanner involves more than just the correct match of the nut or bolt. The jaws of the spanner must be positioned so that the dynamic forces are imposed entirely upon the flats of the nut. If the spanner is too high or not fully engaged accidents will result. In the case of an open ended spanner, it is preferable to pull towards the shorter jaw. This ensures that the maximum turning effect is achieved. In fact, any use of an open- ended or ring spanner should find you pulling the shaft of the spanner towards you and not pushing it away. This is to prevent injury to your hands should the nut suddenly give way. All spanners should be inspected prior to use. Defects to look for are cracks, worn jaws, rounded internal serrations, anything that might cause the spanner to slip under pressure. Always anticipate the possibility of unexpected sudden movement and support yourself accordingly. When working in confined spaces rotate the spanner along its long axis so that the angle of the head is reversed. Then, turn the nut again and repeat the sequence until the nut is loosened. Adjustable Spanner Because you can't always have a complete set of fixed spanners at your disposal, adjustable spanners are a convenient alternative. Position the spanner on the nut with the fixed head away from you. Tighten the movable jaw firmly against the nut by rotating the knurl with your thumb. Then simply pull the shaft towards you as you would with a fixed spanner. Because every job is different there are an endless number of situations we could show you. But one thing remains the same - there is always the right tool for each job. 6

7 Learn the range of spanners available to you and your work will become easier and more efficient. Pipe Wrenches Stillson pipe wrenches are used for screwing in pipes. Because they are designed with serrated teeth to bite into the pipe for a strong grip they should not be used on polished or plated surfaces. This tool requires the use of both hands. After centering the pipe against the lower fixed jaw tighten the adjustable nut until the hardened serrations of both jaws grip the pipe firmly. Pull on the handle to turn the pipe. When re-adjusting the wrench to take another turn support the jaws with your left hand so that they remain in the same position. Once the pipe is screwed in, file off any burrs which the serrated teeth have caused. Screwdrivers It's probably because it's such a simple tool, that the screwdriver is often misused. There's a wide range of screwdrivers available. For each job you face, you must learn to select the one that is the right size, has the correct head shape and is the safest to use. When selecting a standard screwdriver be certain that the tip is almost as thick and as wide as the slot of the head of the screw. This minimizes the risk of slipping which can damage either the work or yourself. A tip of the correct size requires a minimum of downward pressure. Stubby or Dumpy screwdrivers are designed for applications with limited space. When working with live electrical parts always use screwdrivers which are insulated. Phillips Head and Pozidriv are the most commonly used screwdrivers for recessed head screws. Their advantage over standard heads is that they are less likely to slip and damage the work. Safe operation of a screwdriver demands that certain rules be observed. First; the screwdriver must be the right size and its head must match the screw. Inspect the condition of the tip. Make sure the screw head is free of any paint or excess dirt which might interfere with the fit of the screwdriver 7

8 The handle should be clean and undamaged. Support the work on a bench or in a vice if necessary. Never hold a small piece of work in one hand. If the screwdriver slips you might stab yourself. Keep the axis of the blade and the screw in line with each other. Guide the shaft with your off hand but keep it out of harm s way in the event the screwdriver should slip. Never use a screwdriver for anything other than the work for which it is intended. Pliers There are many types of pliers available. These are classified by type and length. Different jaw shapes are suited to a variety of purposes such as; Gripping Cutting Holding Twisting Turning. Many combine different capabilities. Diagonal Cutting pliers are used to cut electrical wires in confined spaces. Their handles are usually insulated. Beware of the danger inherent in flying bits of wire. Point the free end of wire away from you when cutting. Eye protection is also advised. Round Nosed pliers are good for holding particularly small parts. They are most commonly used to form wire loops. Flat nosed pliers with their tapered wedged shaped jaws grip tightly and are good for bending and shaping strips of metal and wiring. Slip Joint pliers are probably the most common type found in household toolboxes. Their jaw openings are variable because of their shifting pivot pin design. This makes them particularly suitable for gripping and maintenance work. Combination pliers as their name describes are designed for multiple capabilities. Their serrated flat jaw tips are excellent for gripping. 8

9 The pipe grip is intended for use on cylindrical objects. Side cutters are used on soft wires. While the joint cutters are designed to accommodate sturdier steel wires. Hammers The range of hammers available is as wide as the uses to which they can be put. Besides the hard metal heads with which we're all familiar with, they can be constructed of soft metal, plastic, wood or even hide. The handles are wood, fiberglass or steel. The weight of the hammer is the primary consideration when making a selection for a particular task. Because of the kinetic forces which are generated by a swinging hammer, safe work practices are important. First clean your hands, the handle and the head of the hammer of any oil, grease or dampness. This will prevent the hammer from slipping out of your hands or off the piece of work. Make sure the head is securely fastened to the handle and the striking face is in good condition. Inspect the handle. Is it cracked or split? If so, replace it. When using tools like chisels and punchers, be certain their heads are clean and dry; otherwise the hammer blow might deflect them dangerously. Hold the hammer well down the handle, a natural grip which will prevent you from tiring is best. Your stance should be comfortable and balanced. But first practice light tapping until you become comfortable with the proper wrist action. Next, incorporate the swing by pivoting your arm at the elbow. Practice until you are able to smoothly combine the movements of your wrist and arm. When you are able to consistently strike the same spot squarely and with equal force then you've mastered the skill. Hacksaws Most hacksaws have adjustable frames which allow blades of various sizes to be used. The two types of blades generally associated with hacksaws are composed of low tungsten steel and high speed steel. 9

10 Low tungsten blades come in two categories: Those which are hardened throughout, and those which are more flexible and hardened only on the cutting edge. The latter are best when working in awkward situations and when learning to use the hacksaw. Their flexibility makes them much less likely to break. Blades which are hardened throughout make accurate sawing much easier. They also have a longer life. But they should only be used by experienced craftsmen as they are brittle and prone to breaking. High speed blades are hardened throughout. Not only do they allow faster work but they possess the longest blade life. Again they should only be used by skilled tradesmen. If the blade moves sideways when cutting, more tension is required. A new blade often needs re-tightening even after the first few strokes. There are some important safety procedures to keep in mind when working with a hacksaw; Wear goggles Support the material being cut Clear away metal chips with a brush, and File off the burrs of finished work. The cut should begin at the back of the work piece with the blade held at a slight angle. To achieve the best cutting technique remember to use both hands for control and keep the blade straight and upright so it doesn't bend or twist. The blade should gradually be brought to the horizontal as the cut widens. Most of the downward pressure should be applied with your leading hand which is at the front of the frame. As the blade moves along the cut, this pressure can be transferred to the driving hand. There should be no pressure on the return stroke as the blade only cuts when it is moving forward. When the cut is nearly completed, shorten your stroke, decrease pressure and if necessary support the stock which is being cut off. After you have finished using your hacksaw the tension should be eased. Regular cleaning and oiling of the tension device is also advised. This presentation has given you an overview of a variety of hand tools, design principles, maintenance, safety procedures and of course techniques and applications. 10

11 If you encounter difficulties or you're uncertain about anything to do with these tools, please don't hesitate to talk to your supervisor. Remember, safety comes first. 11

12 PART ONE SPANNERS There are four basic types of spanners. Open-ended spanners can be either single or double ended. Tube spanners come with an associated 'Tommy Bar' and are useful for reaching nuts in recessed areas. Ring spanners, because of their round shape, are handy when obstructions crowd the sides of the nut. Socket spanners are versatile tools because of the wide range of accessories and adaptors available. Their design which incorporates from 4 to 12 points allows for a number of engaging positions. Of foremost concern in selecting the right spanner for a job is that the correct fit is achieved. Using a spanner which is not properly matched for the nut or bolt is not only dangerous to you but can also damage the spanner or nut making further work difficult. The correct spanner for a particular job is determined by the size of the nut or bolt and the thread system. Even though the size discrepancy between conflicting systems may seem slight, any excess clearance runs the risk of the spanner slipping under pressure. This will result in damage and perhaps injury. DISCUSSION What type or types of spanners are commonly used in your workplace? 12

13 PART TWO ADJUSTABLE SPANNER Because you can't always have a complete set of fixed spanners at your disposal, adjustable spanners are a convenient alternative. Position the spanner on the nut with the fixed head away from you. Tighten the movable jaw firmly against the nut by rotating the knurl with your thumb. Then simply pull the shaft towards you as you would with a fixed spanner. Because every job is different there are an endless number of situations we could show you. But one thing remains the same - there is always the right tool for each job. Learn the range of spanners available to you and your work will become easier and more efficient. DISCUSSION Are adjustable spanners used in your workplace? 13

14 PART THREE SCREWDRIVERS It's probably because it's such a simple tool, that the screwdriver is often misused. There's a wide range of screwdrivers available. For each job you face, you must learn to select the one that is the right size, has the correct head shape and is the safest to use. When selecting a standard screwdriver be certain that the tip is almost as thick and as wide as the slot of the head of the screw. This minimizes the risk of slipping which can damage either the work or yourself. A tip of the correct size requires a minimum of downward pressure. Stubby or Dumpy screwdrivers are designed for applications with limited space. When working with live electrical parts always use screwdrivers which are insulated. Phillips Head and Pozidriv are the most commonly used screwdrivers for recessed head screws. Their advantage over standard heads is that they are less likely to slip and damage the work. Safe operation of a screwdriver demands that certain rules be observed. First; the screwdriver must be the right size and its head must match the screw. Inspect the condition of the tip. Make sure the screw head is free of any paint or excess dirt which might interfere with the fit of the screwdriver The handle should be clean and undamaged. Support the work on a bench or in a vice if necessary. Never hold a small piece of work in one hand. If the screwdriver slips you might stab yourself. Keep the axis of the blade and the screw in line with each other. Guide the shaft with your off hand but keep it out of harm s way in the event the screwdriver should slip. Never use a screwdriver for anything other than the work for which it is intended. 14

15 DISCUSSION Screwdrivers are often misused and a makeshift tool for something else. What are some common ways screwdrivers are incorrectly used? 15

16 PART FOUR PLIERS Different jaw shapes are suited to a variety of purposes such as; Gripping Cutting Holding Twisting Turning. Many combine different capabilities. Diagonal Cutting pliers are used to cut electrical wires in confined spaces. Their handles are usually insulated. Beware of the danger inherent in flying bits of wire. Point the free end of wire away from you when cutting. Eye protection is also advised. Round Nosed pliers are good for holding particularly small parts. They are most commonly used to form wire loops. Flat nosed pliers with their tapered wedged shaped jaws grip tightly and are good for bending and shaping strips of metal and wiring. Slip Joint pliers are probably the most common type found in household toolboxes. Their jaw openings are variable because of their shifting pivot pin design. This makes them particularly suitable for gripping and maintenance work. Combination pliers as their name describes are designed for multiple capabilities. Their serrated flat jaw tips are excellent for gripping. The pipe grip is intended for use on cylindrical objects. Side cutters are used on soft wires. While the joint cutters are designed to accommodate sturdier steel wires DISCUSSION What are the common types of pliers in your workplace, and what tasks are they used for? 16

17 PART FIVE HAMMERS The range of hammers available is as wide as the uses to which they can be put. Besides the hard metal heads with which we're all familiar with, they can be constructed of soft metal, plastic, wood or even hide. The handles are wood, fiberglass or steel. The weight of the hammer is the primary consideration when making a selection for a particular task. Because of the kinetic forces which are generated by a swinging hammer, safe work practices are important. First clean your hands, the handle and the head of the hammer of any oil, grease or dampness. This will prevent the hammer from slipping out of your hands or off the piece of work. Make sure the head is securely fastened to the handle and the striking face is in good condition. Inspect the handle. Is it cracked or split? If so, replace it. When using tools like chisels and punchers, be certain their heads are clean and dry; otherwise the hammer blow might deflect them dangerously. Hold the hammer well down the handle, a natural grip which will prevent you from tiring is best. Your stance should be comfortable and balanced. But first practice light tapping until you become comfortable with the proper wrist action. Next, incorporate the swing by pivoting your arm at the elbow. Practice until you are able to smoothly combine the movements of your wrist and arm. When you are able to consistently strike the same spot squarely and with equal force then you've mastered the skill. DEMONSTRATION With a hammer commonly used in your workplace, demonstrate the correct way to hold and use it. Also show some common incorrect ways people use hammers. 17

18 PART SIX HACKSAWS Most hacksaws have adjustable frames which allow blades of various sizes to be used. The two types of blades generally associated with hacksaws are composed of low tungsten steel and high speed steel. Low tungsten blades come in two categories: Those which are hardened throughout, and those which are more flexible and hardened only on the cutting edge. The latter are best when working in awkward situations and when learning to use the hacksaw. Their flexibility makes them much less likely to break. Blades which are hardened throughout make accurate sawing much easier. They also have a longer life. But they should only be used by experienced craftsmen as they are brittle and prone to breaking. High speed blades are hardened throughout. Not only do they allow faster work but they possess the longest blade life. Again they should only be used by skilled tradesmen. If the blade moves sideways when cutting, more tension is required. A new blade often needs re-tightening even after the first few strokes. There are some important safety procedures to keep in mind when working with a hacksaw; Wear goggles Support the material being cut Clear away metal chips with a brush, and File off the burrs of finished work. The cut should begin at the back of the work piece with the blade held at a slight angle. To achieve the best cutting technique remember to use both hands for control and keep the blade straight and upright so it doesn't bend or twist. The blade should gradually be brought to the horizontal as the cut widens. Most of the downward pressure should be applied with your leading hand which is at the front of the frame. As the blade moves along the cut, this pressure can be transferred to the driving hand. There should be no pressure on the return stroke as the blade only cuts when it is moving forward. 18

19 When the cut is nearly completed shorten your stroke, decrease pressure and if necessary support the stock which is being cut off. DISCUSSION What materials are hacksaws designed to cut? 19

20 ASSESSMENT HAND TOOLS: SAFETY AND TECHNIQUE Name: Date:. I.D. (if applicable): Score 1. When working around electrical sources, what type of screwdriver should you use? a) Insulated b) Stubby c) Phillips Head d) Metal 2. What are pliers commonly used for? a) Gripping b) Holding c) Twisting d) All of the above 3. When cutting wire with diagonal cutting pliers, what should be done with the free end of wire? a) You should hold it b) You should point it away from you c) You should rest it on the ground d) All of the above 4. Which of these is not a type of hammer head? a) Cloth b) Wood c) Hide d) Hard metal 20

21 5. If a hammer handle is cracked or split, what should you do? a) Complete the job you are doing then re-assess it b) Replace it immediately c) Nothing d) None of the above 6. What are the 2 blade types commonly associated with hacksaws? a) Saw and Blade b) Steel and Aluminium c) Low Tungsten Steel and High Speed Steel d) Carbon Fibre and Teflon 7. When does a hacksaw blade perform its cutting action? a) Both when moving forward and backward b) On the forward stroke only c) On the backward stroke only d) Whenever enough downward pressure is applied. 8. What safety procedure/s should you keep in mind when using a hacksaw? a) Wear safety glasses or goggles b) Support the material being cut c) Clear away metal chips with a brush d) All of the above 9. When should you ease the tension on a hacksaw blade? a) Never b) Only when changing the blade c) At the end of each job d) When working on a hard metal 10. What are pipe wrenches not suitable to be used on? a) Polished or plated surfaces b) Large pipes c) Small pipes d) Pipes that have been previously worked on 21

22 ANSWERS TO ASSESSMENT 1. A) Insulated 2. D) All of the above 3. B) You should point it away from you 4. A) Cloth 5. B) Replace it immediately 6. C) Low Tungsten Steel and High Speed Steel 7. B) On the forward stroke only 8. D) All of the above 9. C) At the end of each job 10. A) Polished or plated surfaces 22