Principles of Hand Tool Selection

Loss Prevention Reference Note

Repetitive use of manual This reference note gives some of the ergo- or powered hand tools is often nomic principles that can help guide you in a factor in carpal tunnel syn- selecting the proper manual or powered hand drome and other hand and wrist tools for repetitive tasks. disorders. While most tools are General Principles satisfactory for general purpose use, they may be entirely inappropriate for con- Before selecting any tool, you should first tinual or repetitive use in a production situation. ensure that the work area is ergonomically sound in For instance, a 15-pound hand tool may be per- terms of work surface height, adjustable seating, fectly acceptable for occasional use,1 but tools that acceptable manual handling requirements, etc. (See are used frequently or repetitively should weigh no LP 185, “Ergonomic Recommendations for Work- more than 4 pounds (1.75 kg).2 In addition, the place Design.”) Tilting the work surface or using working environment as a whole may also have fixtures to hold, tilt, or rotate the work can help to be evaluated and corrected. A properly designed minimize awkward wrist motions and simplify hand tool used in an awkward posture will not tool selection. solve the problem. Powered hand tools, rather than manual, Hand tools vary con- Characteristics to Avoid should be used whenever siderably in shape, size, When Selecting Hand Tools possible, because re- and weight. The way a peated manual exertion tool is designed influ- ■ Sharp edges and corners on tool handles. is more likely to cause ences the hand positions ■ Narrow handles, which concentrate large discomfort and injury. and motions that are re- forces into small areas of the hand. Look for tool designs quired to use it. Fortu- ■ Smooth or highly polished handles. that allow the user to keep nately, there are typically ■ Form-fitting handles or handles with the elbows in close to the several designs to choose recesses that fit only one size of hand. body. While using a hand from in each tool cat- ■ Sharply curved handles – the curvature tool, the worker should not egory. Ask workers for should be less than 0.5 inches (1.3 cm) have to reach more than their opinion about the over the length. 15 inches (38 cm). The tools you provide. ■ Scissors and shears with finger loops that tool design should also al- cause excessive pressure on the thumb Ease of maintenance and fingers (if possible, use power cutters low users to keep their and repair should also be instead). forearms at right angles to a consideration in tool se- ■ Tools that require workers to use a pinch the upper arms, and the lection. Proper mainte- or precision grip. wrists straight or in a natu- nance, such as keeping ■ Short tool handles that press into the palm ral position. It is much bet- bits sharp, will help mini- of the hand. ter to bend the tool than to mize forces. bend the wrist.

LP 190 R4 © 2004 Liberty Mutual Group - All Rights Reserved January 2001 Power tool models may have pistol-grip, right-angle grip, or in-line handles. Pistol-grip tool handles should be at an angle of approxi- mately 80°11 from the long axis of the tool. In- line tool handles may have straight, offset, or right-angled heads. Hand tools such as pliers can be obtained with bent handles (so-called ergonomic pliers) or in curved-nose models. Caution is advised when using bent-handled tools in the workplace. The optimum angle with respect to wrist deviation depends on the height of work. Research has shown bent-handled tools are best used when work heights are located at elbow height. Workspaces at elbow height opti- mize straight wrist operations and performance. However, workspaces with work heights above or below elbow height increase wrist deviation and decrease performance.10 The appropriate diameter of the handle (or the part of the tool that the user holds) depends on the way it is gripped and the size of the worker’s hand. As Figure 1 shows, the recommended diameter for tools that require a power grip is in the range of 1 to 1.6 inches (2.5 to 4 cm); for a hook grip 0.80 inches (2 cm); and for a precision or pinch grip at least 0.25 inches (0.6 cm). Figure 1. Recommended tool handle Manual Hand Tools diameters for various grips. When selecting manual hand tools, look for tool designs that have the following features: If possible, select tools that can be used with ■ either hand. This not only helps accommodate Handles that use a power grip and that are left-handed workers, but for some tasks, it lets longer than hand breadth – that is, at least 4 inches (10.2 cm), but preferably more than 5 workers switch hands to reduce the repetitive 3 stress on either hand. Many hand tools normally inches (13 cm) long. designed for right-handed use are also available ■ Different sizes for workers with different in left-handed versions. sized hands. The handle diameter should be 0.4 inches (1 cm) smaller than the user’s grip Tool Handles diameter measured with the thumb meeting Handles should be slip-resistant, either by the middle finger. material or by design. If available, select tools ■ A handle which, when gripped, distributes with rubber or plastic foam-covered handles or forces over all fingers and the entire surface grips. This cushioning helps to cover sharp edges, of the palm. increases the diameter of narrow handles, and provides a more slip-resistant and comfortable The following guidelines apply to pliers- grip. On some power tools, it may also help to type manual hand tools, including wire cutters, dampen the effects of tool vibration. scissors, and pop riveters:

2 at or below elbow height. If the work cannot be kept at this level, use tools with in-line handles.5 ■ If the tool is operated by means of a trigger, consider tools with an extended trigger that 4 inches can be operated by two or more fingers together, or tools with a thumb trigger (the thumb is much stronger than the other fin- ■ When the pliers are fully closed, the space gers). Avoid designs where the index finger between the pliers handles should be at least will be overused for triggering. 1 inch (2.5 cm). For tools that are squeezed ■ The tool’s with two hands, the space should be at least center of grav- 2 inches (5.1 cm). ity should ■ If the pliers- align with the type handles center of the must be g r a s p i n g opened and hand, so that closed during the hand will tool opera- not have to tion, they compensate should be no for rotational moments or torque of the tools. more than 4.5 ■ inches apart Power tools should be designed to minimize (11.5 cm) when fully opened (this is the open vibration, rotational torque, or impact forces grip span). on the hand and wrist. ■ If high squeeze forces are required, the grip Force Guidelines span should be in the range of 2 to 2.4 inches Much of the research data on hand tools (5 to 6 cm).4 The smaller size is better for comes from studies of grip strength at a variety users with small hands. of postures and psychophysical methodology. ■ For tasks requiring sustained effort (£1 min.), Psychophysical methodology is what people grip forces should not exceed 25 pounds feel to be the “right” weight, maximum force, or (11.3 kg) for ungloved hands, and 22 pounds size in some cases. (10.2 kg) for gloved hands. The data in Table 1 (next page) come prima- ■ Spring action should return the handles to rily from psychophysics and can be used to the open position. identify what a large percentage of the popula- tion can do without overexertion. In general, the ■ If the handle has an opening for fingers (e.g., maximum acceptable force for repetitive exer- conventional snips or scissors), the handle tion is 30% of a maximum voluntary contraction should allow at least 5 inches (12 cm) spread (MVC).6 for the fingers and an additional 1 inch (2.5 For example, a worker who can grip a tool cm) if gloves are worn.3 with 15 pounds of force at his or her MVC should Powered Hand Tools only use a 4.5-pound grip (30% of 15 pounds) to When selecting power tools, keep these con- avoid overexertion during repetitive tasks. siderations in mind: Some of the force and torque requirements ■ For power tool use on a horizontal surface, of a task are difficult to measure. Consult your adjust the surface height so that the work is kept Loss Prevention consultant for assistance.

3 5. Ulin, S., Armstrong, T., Snook, S., and Table 1. Force Guidelines For Tool Selection Franzblau, A., “Effect of tool shape and Power Grip work on perceived exertion for work on Occasional...... 25 pounds for 2.5- to 3.5-inch horizontal surfaces,” American Industrial grip; 10 pounds for <2-inch Hygiene Journal, 54(7): 303-391, 1993. 3 grip 6. van Wely, P., “Design and disease,” Applied Frequent ...... 4.8 pounds for <2-inch grip7 Ergonomics, 1:262-269, 1970. Pinch Grip 7. Rodgers, S.H., In Ergonomic Design for Frequent ...... 2.2 pounds7 People at Work, Eastman Kodak Company, Wrench (8-inch) Van Nostrand Reinhold, New York, 1986. User Standing...... 44 inch-pounds8,1 8. Mital, A., and Channaveeraiah, C., “Peak User Sitting...... 29 inch-pounds8,1 volitional torque for wrenches and screw- Socket Wrench (10-inch) drivers,” International Journal of Industrial User Standing...... 53 inch-pounds8,1 Ergonomics, 3:41-64, 1988. User Sitting...... 37 inch-pounds8,1 9. Tichauer, E., and Gage, H., “Ergonomics principles basic to hand tool design,” Ameri- Screwdriver (10-inch) 8,1 can Industrial Hygiene Association Journal, User Standing...... 4 inch-pounds Akron, 38:622-634, 1978. User Sitting...... 5 inch-pounds8,1 10. Dempsey, P.G., Leamon, T.B., “Implement- Rotating Tools ing bent-handled tools in the workplace”, In-Line Handles ...... 12 inch-pounds9 Ergonomics In Design, 15-21, 1995. Trigger Forces 11. Mital, A., Kilbom, A., “Design, selection Single-Finger Trigger.2.2 pounds7 and use of hand tools to alleviate trauma of Note: These grip forces should be reduced by at the upper extremities: Part 1 – Guidelines for least 25% if the tool user wears gloves. the practitioner”, International Journal of Industrial Ergonomics, 10:1-5, 1992. References 12. Mital, A., Kilbom, A., “Design, selection and use of hand tools to alleviate trauma of 1. Chaffin D., “Localized muscle fatigue, defi- the upper extremities: Part II – The scientific nition and measurement,” Journal of Occu- basis (knowledge base) for the guide”, Inter- pational Medicine, 15:346, 1973. national Journal of Industrial Ergonomics, 2. Armstrong, T., Punnett, L., and Ketner, P., 10:1-5, 1992. “Subjective worker assessments of hand tools 13. Mital, A., Kumar, S., “Human muscle used in automobile assembly,” American strength definitions, measurement, and us- Industrial Hygiene Association Journal, age; Part I – Guidelines for the practitioner:, 50(12):639-645, 1989. International Journal of Industrial Ergo- 3. Chaffin, D., and Andersson, G., In Occupa- nomics, 22:101-121, 1998. tional Biomechanics, John Wiley & Sons, 14. Mital, A., Kumar, S., “Human muscle New York, 1984. strength definitions, measurement, and us- 4. Oh, S., and Radwin, R., “Pistol grip power age; Part II – The scientific basis (knowl- tool handle and trigger size effects on grip edge base) for the guide”, International exertions and operator performance,” Hu- Journal of Industrial Ergonomics, 22:123- man Factors, 35(3), 551-569, 1993. 144, 1998.

The illustrations, instructions and principles contained in the material are general in scope and, to the best of our knowledge, current at the time of publication. No attempt has been made to interpret any referenced codes, standards or regulations. Please refer to the appropriate code-, standard-, or regulation-making authority for interpretation or clarification. Provided that you always reproduce our copyright notice and any other notice of rights, disclaimers, and limitations, and provided that no copy in whole or in part is transferred, sold, lent, or leased to any third party, you may make and distribute copies of this publication for your internal use. 4 Printed in U.S.A.